Sanjay Verma, Wärtsilä: Efficient power solution for Floating LNG

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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/flngforum2013

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Sanjay Verma, Wärtsilä: Efficient power solution for Floating LNG

  1. 1. Efficient Power Solution For Floating LNG The FLNG Forum Sanjay Verma - Area Sales Director 3rd- 4th Dec 2013 1 © Wärtsilä December 4, 2013 Efficient energy for Offshore Production units
  2. 2. Agenda • • • • • • • • 2 Introduction to Wartsila Setting the Scene – Why Change? Efficient Energy References Operation & Management Condition based maintenance Comparison Conclusion © Wärtsilä December 4, 2013 Efficient energy for Offshore Production units
  3. 3. Financial Highlights 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 1.72 1.44 1.96 1.97 Earnings/share, EUR 3 © Wärtsilä 4.12.2013 Efficient energy for Offshore Production units
  4. 4. Wärtsilä – Overview 22,000 professionals Solutions for Marine/ offshore Energy Ship Power 26% (34) Power Plants 34% (31) • Listed in Helsinki Services 40% (35) 4 © Wärtsilä 4 December 2013 Efficient energy for Offshore Production units
  5. 5. Wartsila expertise in the Oil & Gas value chain LNG terminal & Regasification (FSRU/JRU) Distribution & transport Power generation LPG/LEG/LNG tanker Small-scale LNG plants LNG receiving terminal LNG liquefaction & terminal LNG carrier LNG fuelled vessels LNG fuelled vessels Oil tanker with VOC Production Exploration & development Exploration & Drilling • LNG fuel gas systems for OSVs 5 © Wärtsilä FPSO Flare recovery Oil separation Production & liquefaction • On- & Offshore small scale liquefaction • Antiflaring/VOC • Oil separation • Gas FPSO LNG bunkering & barges Transport & storage Receiving terminals & regasification • LNG fuel gas systems • Jetty & Floating regasification • LPG, LEG & LNG cargo handling • Bunkering & barges • Receiving terminals Distribution & transport to the users • Gas/LNG distribution/logistics • Feed gas to Power plants
  6. 6. Liquefaction Liquids extraction LNG reliq Pre-treatment LPG reliq
  7. 7. 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 7 © Wärtsilä 04 December 2013 WÄRTSILÄ Hamworthy
  8. 8. Products and Solutions for Offshore Production • 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 8 © Wärtsilä May 24, 2012 Wartsila provides Life Cycle Support to all its Customers through our service centers around the globe Efficient energy for Offshore Production units
  9. 9. WÄRTSILÄ OFFSHORE – FPSO & FLNG OFFSHORE Flow Solutions Oil and Gas Solutions DWP FLNG FWPP ERP PRS LNG LPG √ √ √ √ √ √ √ √ Type √ √ √ √ √ √ FPSO 9 © Wärtsilä 04 December 2013 Presentation name / Author, Document ID: Drives Electrical GR DF DG IGG Thrusters √ √ √ √ √ √ √ √ √ √
  10. 10. 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? 10 © Wärtsilä 4 December 2013 Efficient energy for Offshore Production units
  11. 11. 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 11 © Wärtsilä 4 December 2013 Efficient energy for Offshore Production units
  12. 12. 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 12 © Wärtsilä 04 December 2013 Efficient energy for Offshore Production units
  13. 13. Dual Fuel/Gas & Crude Oil Engine Technologies Gas-diesel (GD) engines: Spark-ignition gas (SG) engines: Dual-fuel (DF) engines: • Runs on various gas / diesel mixtures or alternatively on diesel. • Runs only on gas. • Runs on gas with 1% diesel (gas mode) or alternatively on diesel (diesel mode). • Combustion of gas, diesel and air mixture in Diesel cycle. • Combustion of gas and air mixture in • Combustion of gas and air mixture in Otto cycle, triggered by spark plug Otto cycle, triggered by pilot diesel ignition. injection (gas mode), or alternatively combustion of diesel and air mixture in Diesel cycle (diesel mode). • High-pressure gas injection. • Low-pressure gas admission. • Low-pressure gas admission. Dual-fuel (DF) engines – Multiple fuel engines Spark-ignition gas (SG) engines Gas-diesel (GD) engines ‘87 … ‘92 ‘93 ‘94 ‘95 ‘96 ‘97 ‘98 ‘99 ‘00 ‘01 ‘02 ‘03 ‘04 ‘05 ‘06 ‘07 ‘08 ‘09 ‘10 ‘11 ‘12
  14. 14. Dual-Fuel Engine Portfolio 20DF 6L20DF 1.0 MW 8L20DF 9L20DF 34DF 6L34DF 9L34DF 12V34DF 16V34DF 20V34DF 50DF 6L50DF 8L50DF 9L50DF 12V50DF 16V50DF 18V50DF 0 17.55 MW 5 10 15
  15. 15. 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. 16. Typical gas turbine efficiency versus Wärtsilä 50DF 18000 Low efficiency Heat rate [kJ/kWh] 16000 Gas Turbine 14000 12000 10000 8000 Wärtsilä 50DF 6000 20 High efficiency 30 40 50 60 70 80 90 Load [%] Wärtsilä 50DF versus Gas Turbine at 35ºC  Wärtsilä DF engine do not face the same challenges in tropical environment ! 100
  17. 17. Gas turbine and Wärtsilä DF gensets W12V34DF vs. 7 MW Gas Turbine Specific fuel consumption SFOC [g/kWhr] Max. power limit Gas turbine genset Note: large difference in low load operation Wärtsilä DF genset SFOC [g/kWeh] For example: At 25°C -60%MCR: DF: abt 225 g/kWeh GT: abt 310 g/kWeh Temperature [ºC] 04 December 2013 Output (% of the MCR output in 15ºC, i.e. ISO conditions)
  18. 18. 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 Engine Load 100% 80% 0% Gas mode Diesel mode
  19. 19. Typical plant efficiency at full output Typical shaft efficiencies - simple cycle prime movers – No de-rating due to ambient temperature 48% 37 % 30% Small Size Gas Turbine Big Size Big Size DF Gas Turbine Engine 35 % Power available in exhaust gas that can be recovered as steam or hot Water/Oil
  20. 20. 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 Navy Others LNG Cruise ferry • 1 vessels • 4 engines • Complete gas train Coastal Patrol • DF-propulsion • DF main and auxiliary engines TUG • 2 vessel • 2 engines each • Mechanical drive Guide Ship • 1 vessel /engine IWW • 2 vessel • 3 engines LNG ferries • 2 ferries • 8 engines • Complete gas train  6 segments  >230 installations  > 7’000’000 running hours © Wärtsilä
  21. 21. 35 MW x 3 Modules for P-63 FPSO 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. 6 x Wartsila 18V50DF COSCO Shipyard Dalian 21 © Wärtsilä 04 December 2013 Efficient energy for Offshore Production units
  22. 22. 22 © Wärtsilä 04 December 2013 Corporate Presentation
  23. 23. 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) 23 © Wärtsilä 4 December 2013 Efficient energy for Offshore Production units
  24. 24. 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 24 © Wärtsilä December 4, 2013 Efficient energy for Offshore Production units
  25. 25. No essential generators needed 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 25 © Wärtsilä
  26. 26. INTERNAL USE ONLY / CONFIDENTIAL Inboard demountable thruster Patent pending
  27. 27. History History Lips Modular Thruster: ● ● ● ● ● ● 1967: 1972: 1976: 1977: 1981: 1998: first Lips Modular Thrusters (900 kW) first containerised thrusters (1470 kW) first retractable thrusters (2230 kW) first thrusters with controllable pitch propellers first underwater de-mountable thrusters (3000 kW) 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. 28. O&M Agreements 28 © Wärtsilä 04
  29. 29. Wärtsilä O&M references (11/2009) 4 812 MW under contract North America 259 MW South America 1239 MW • • • • • 29 Over 1800 employees 228 installations 160 O&M agreements in 30 different countries (updated 19.11.2009) © Wärtsilä 04 December 2013 Europe 122 MW Africa 805 MW Middle East 1189 MW Asia 319 MW India 879 MW Total of 4 812 MW under contract Marine 112 ships under agreements
  30. 30. 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
  31. 31. Wärtsilä’s Service Agreement types Supply Agreements • Manpower • Spare Parts • Workshops • Online Solutions Technical Management • Dynamic Maintce Planning • Risk Evaluation • Inspection • Training and competences • Planning support Maintenance Agreements • Manpower & Parts • Performance Guarantee • Global Coordination & Supply Asset Management • Operations & Maintenance • Part Crew • Equipment • Installation
  32. 32. Asset crew Concept Onboard Maintenance Crew Crew Centralised Management Spare parts © Wärtsilä 32
  33. 33. Condition Based Maintenance Concept Dynamic Maintenance Planning 33 © Wärtsilä 04 December 2013 Efficient energy for Offshore Production units Wärtsilä 24/7 Concept
  34. 34. CASE STUDY Power Generator Selection 70 MW - 1/3 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 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 17.9 358 414.1 (*1) 1) FG cost: 4.8 US$/MMBTU 2) The above costs and foot print of Gas Turbines are market estimates 3) Foot print area does not cover the foot print required for additional skids (Superheat module, gas pressure module & also gas accumulators)
  35. 35. CASE STUDY Power Generator Selection 70 MW - 2/3 Gas Turbine Gas Engine (Dual Fuel) Top Side Hull Fuel Gas Pressure High Pressure 45 barg Low Pressure 6 barg Fuel Gas dryness +28 oC Superheated No requirement Gradual controlled change (30 – 60 seconds) Instant change Not required Required (1% of energy consumption) Installation Switching fuel from gas to diesel Pilot oil
  36. 36. CASE STUDY Power Generator Selection 70 MW - 2/3 Reliability and Availability PGT25+G4
  37. 37. CASE STUDY Power Generator Selection 70 MW - 3/3 COMPARISON OF MAINTENANCE Generator Number Maintenance Cost (US$/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 *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. 38. Wouldn’t you like this as a free area for easier topside layout? 38 © Wärtsilä 04 December 2013 Presentation name / Author Sanjay Verma
  39. 39. 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
  40. 40. 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
  41. 41. 41 © Wärtsilä 04 December 2013 Corporate Presentation
  42. 42. Conclusion 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 42 © Wärtsilä 04 December 2013 Efficient energy for Offshore Production units

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