© ABB Group November 19, 2013 | Slide 1
Energy efficiency: Increasing competitiveness and reducing environmental impact by utilizing all electrical solution for FLNG
Stein Guldbrandsøy/, ABB Chemical Oil, & Gas
Agenda.
1. Introduction to ABB OGP
2. ABB in FPSO,LNG and Floating LNG
3. All electric solutions for LNG and FLNG
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© ABB Group November 19, 2013 | Slide 3
© ABB Group November 19, 2013 | Slide 3
ABB in Oil, Gas & Petrochemicals
Over 50 years of experience in the OGP Industry.
≈ 2,800 successfully completed projects worldwide.
≈ >70 active FPSOs, more than 100 LNG carriers
Industrial solutions supplier of products, automation
systems, electrification, telecoms, specialized EPC
projects, and services.
ABB 2012 Sales in the Oil, Gas and Petrochemical
Market, in excess of $4.5 billion (systems and
products).
Over 25 000 Employees globally available for OGP
Over 8,000 dedicated oil and gas engineers in 40
countries
FPU Centre Of Excellence in Norway
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Sales / Engineering
Service Centres
Full Service
Turbocharging
Perth
Brisbane
Sydney
Melbourne Latrobe Valley
Port Kembla
Darwin
Kwinana
Newcastle
3
3
Gladstone
Adelaide
ABB in Australia Engineering and Service Centers
Electrical Complete single line
Drives & motors
Drilling solutions
Field instrumentation,
level, pressure, temperature, flow
Third party incl valves
Automation, ICSS & PMS PCS, ESD, PSD, F&G, PMS
IMS and Condition Monitoring
Lifecycle simulation
Control room design
Telecom system integrator Infrastructure
20+ subsystems
Integrated Opeations/Digital Oilfield
Packaging – E-house, power skids
Electrification – Pfs
Subsea power
ABB offering What we offer today
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Subsea solutions
Step
down DC
M
DC
transmission
Step
down AC
M
AC
transmission
Subsea
drive
High
speed
machine
High
speed
machine
Subsea
drive
M
Topside
drive
Step-Up
transformer
Step-down
transformer
Long AC
cables
High
speed
machine
To
ps
ide
/sh
ore
S
ub
se
a
Today Ongoing Future
+ Subsea O&G processing
+ No platforms/floaters
+ One cable over many
+ Longer distance
– Limited distance
Subsea AC
+ Subsea O&G processing
– Platforms/floaters needed
– Many cables needed
– High OPEX, CAPEX
– People safety procedures
– Environmental impact
– Limited step-out distance
+ Subsea O&G processing
+ No platforms/floaters
+ One cable
+ Cheaper cable
+ Longest distance
+ Common DC: no rectifiers
Topside AC Subsea DC
World longest cable connected to frequency converter output (47km)
Biggest power rating for step-out system (Rated 15MVA Transmission)
Highest supply frequency for long step-out system (up to 200Hz)
Qualifying, building and testing
Converter (15MVA/200Hz, for Long Step-out Application)
Step-up Transformer (15MVA/200Hz)
Subsea Transformer (15MVA/200Hz)
Complete System testing
Detail simulation model of complete system
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Selected references - ABB has delivered to more than 60 FPSO’s Aasta Hansteen, HHI MAC/MEC/MTC (ECT)
Ichthys FPSO, DSME MEC
Ichthys CPF, DSME MEC
PFLNG NR 1 PMS
Prelude FLNG LV SWG
Apache Balnaves, Bumi Armada MAC
D1, Bumi Armada MEC,MAC, E-House
OSX 3, Modec MEC,MAC, E-House
P58/62, Quip MEC, E-House
Knarr/Jordbær, SamsungTeeky MAC
Goliat, ENI /HHI- KR EICT
P-63 Topside , Quip MEC,E-House
Tupi NE, SBM MEC, E-House
Baleia Azul, SBM MEC for MV,LV
Pioneer, BWO Cascade Chinook MAC,MEC
Peregrino - Maersk/Statoil MAC,MEC
Vincent/Nganhurra MAC, MEC
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© ABB Month DD, YYYY | Slide 8
Goliat FPSO – ENI
Goliat field is located in the Barents Sea north of Norway and consists of a FPSO (Sevan concept) and sub sea installation with 32 wells. Startup of the production is in 2013 and the production will be 5.4 million Sm³/year.
ABB Deliveries - FPSO
EICT Electrical, Instrumentation, Control & Telecom supply:
Electrical system
HV, MV and LV Switchgears
Sea cable for electrification from onshore
Drives
UPS
Instrumentation
Field instruments for control & safety
Valves
Control
Power Management System
Process Control System
Process Shutdown System
Emergency Shutdown System
Fire & Gas System
Topside SCU Control System for sub sea (option)
Life Cycle Simulator
•Remote collaboration facilities
•Facilities for condition based maintenance
•Industrial networks & Information security infrastructure
Telecom Systems
FPSO Goliat
Project Background
The world’s biggest central processing facility (CPF) . The offshore facility,
which will produce and process gas off Australia’s northwestern coast, will
measure 110 meters (about 360 feet) in both height and width and weigh
100,000 tons.
The CPF form a core part of the Ichthys LNG project along with a floating
production, storage and offloading (FPSO) vessel. Gas produced in the
CPF will be sent to an onshore LNG plant via 885 kilometer-long underwater
pipeline.
ABB Deliveries:
HV Switchgear - GIS ZX1
HV Switchgear - AIS ZS1
LV Switchboards - MNS iS
Transformers - Liquid Filled IEC Ex
Transformers - Resibloc,Vaccum Cast Coil
Project Management
Engineering
QA / HSE
Project Data Book
Ichthys CPF, SHI, Ichthys FPSO, DSME - Inpex
Project Background
The Balnaves field is located in License WA-356-P offshore Western Australia. Apache operates the license, holding a 65% interest; KUFPEC Australia holds 35%.
Bumi Armada awarded ICSS contract in March 2012 Upon completion, the FPSO Armada Claire will be deployed in the Balnaves Field.
ABB Deliveries:
Responsible for Engineering, Supply and Installation of a new 800xA ICSS System including:
• PCS.
• SIL 3 shutdown system,
• F&G system, with new detectors
FPSO Armada Claire
Woodside (Maersk) Vincent/Nganhurra
The 380,000 dwt tanker Ellen Maersk to be converted to a FPSO at Keppel Shipyard in Singapore in 2007 and renamed Vincent.
When completed in 2008, the FPSO will have a production capacity of 120,000 barrels of oil and 100 million standard cubic feet of gas per day. The storage facilities of the vessel will hold 1.9 million barrels of oil equivalent.
ABB Deliveries:
Topside Process Control
Topside Process Shutdown
Topside Local Equipment room
Safety system
F&G systems
Ex Remote I/O cabinets for PCS, PSD, ESD and F&G
Power Management
Topside LV distribution boards and motor control centre
HV Switchgear
Generators Interface
MV Soft starter.
UPS
Trafo
Ex. Distribution Boards
Maersk Woodside Vincent/Nganhurra
Project Background Queensland Curtis LNG (QCLNG) will be the world's first project to turn gas from
coal seams into liquefied natural gas, or LNG.
The project, which has been under construction since 2010, will provide cleaner
hydrocarbon energy for export markets from 2014.
ABB MAC Deliveries:
FEED Engineering
SPI Engineering
Process Control System
Process Shutdown Systems
Fire & Gas System (SIL 2)
Condition based maintenance systems
Operator training system
Telecoms
85,000 I/O
Queensland Curtis LNG
ABB in LNG – LNG liquefaction LNG Hammerfest FIELD
145 km north-west of Hammerfest, Norway First in Barents Sea. Water depth 250-350 meters, subsea only, Pipeline to processing plant and LNG plant Onshore at Melkerøya, Hammerfest
Daily production from Oct 1, 2006
15 million (scm) of LNG 14.000 barrels of condensate 650 tonnes of LPG
ABB Contracts
Automation scope Instrumentation Analytical instruments Electrical LV Motors LV, MV, HV switchgear PMS Services
ABB Scope
Controllers, Subsea Controllers, 33.600 Field I/O, Workstations, Supervisory system, Low, Medium& High Voltage switchgear, LV Motors, Instrumentation, Analytical, Load Calculations, Selectivity, Loop Design, Configuration, Installation, Commissioning
ABB Highlights
Frame agreement model, collaborative integrated team, Use of large electrical drives, Electrical distribution and power management, Control of subsea installation from shore ABB Analytical equipment for LNG, Control and optimization of LNG process
Photo: Eiliv Leren / Statoil
ABB in LNG -LNG liquefaction LNG Hammerfest
Main process facilities built on a floating barge
Direct flow of unprocessed feed from subsea wells
Full subsea development-remotely operated
Compact layout of process plant
Modularized and prefabricated facilities
Snøhvit field development and Hammerfest plant- a full
LNG value chain
Operation of compact processing facilities
Use of LM 6000 and all Electric solution
Reinjection of CO2 from feed gas
Mixed refrigerant liquuefication process with sea water
cooling
Operation in harch enviroment
Minimized flaring
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Electrification and Energy Efficiency
© ABB Inc. November 19, 2013 | Slide 15
Energy efficiency:
• Your energy efficiency is typically 30% less than optimum.
• Therefore you loose 4% of revenues that could contribute direct to
EBIT.
• It’s about
• Using less energy for the same tasks
• Reduced Product Losses
• Higher Stability resulting in better Safety and Availability
• Reduced Maintenance
• AND Lower emissions
Good for your wallet, good for the environment
Reducing losses along the energy chain
Losses
Primary energy Transport Generation T&D Industrial processes
Industrial production
80% of energy is lost A
va
ilab
le e
ne
rgy
12% In the industry
EROEI Facility power plant (100 kbbl/day)
1930 ≈ 100:1 <1 MW
1980 ≈ 20:1 10 MW
2010 ≈ 10:1 100 MW
Oilsand ≈ 5:1 200 MW
Primary energy Transport Generation T&D Industrial processes
Industrial production
Ava
ilab
le e
ne
rgy
technology can
reduce losses by 20-
30% More efficient fuel
combustion
Higher pipeline
flows
Improved well
efficiency
Power generation
Transport
All electric
Lower line losses, higher substation
efficiency Improved
productivity
More efficient motors & drives
Drives & motors
Process
Automation
Marine & pipelines
Power plant automation
Grid operation
Process automation
Reducing losses along the energy chain Potential increases in efficiency
Why electrification? Energy Efficiency !
Environment
Health and safety
Maintenance
Profitability
Stability
Why electrification? Need to optimize for best performance
Gas turbines (typical aeroderivative)
• Heavy maintenance intensive, cost ~18%
of capex/yr.
• Shutdown ~ 6% of time
• Work with inherent equipment
characteristics power generation system
performance.
Electrification
Reduced fuel gas consumption 30-70%
Higher availability 3-10 on-stream days
Tighter control - Lower recirculation 1-3%
losses
Maintenance cost down 80% less heavy
maintenance
Less ignition points, noise, vibration
Asset management and Energy efficiency
Electrical: Drive power, speed, torque, stall
Process: Flow, Temperature, Pressure, Vibration
Diagnostics:
Wheel wear, Scaling, Motor electrical faults, Efficiency
Why ?
Eliminate in operation failures (3-10 additional uptime days per year)
Reduce periodic maintenance costs by 15-30%
Extend equipment lifetime by 10-30%
Improved Control: Eliminate unstabilities
Compressor anti-surge control tuning - 20% reduced fuel gas consumption (North Sea Field)
– realized due to very tight client/supplier integration
Reduced Fuel Gas Consumption by Controller Tuning
Before After→
Electrification - The Value of Energy Efficiency
Typical 70 MW Facility:
Stability is deferred production and on-stream time
gained due to reduction in trips and scheduled
shutdowns and improved stability (~50%)
Fuel is saved cost of consumed energy (HC)
(~25%)
Maintenance is savings in turbomachinery
maintenance costs. (~15%)
Emissions is savings in emissions quota costs.
(~10%)
Power from (to) Shore solutions
HVDC
HVDC
HVDC
AC
AC
0
50
100
150
200
250
300
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
Distance (km)
Troll A 45 kV
20 MVA 50 km Gjøa 90 kV
45 MW 100 km
Statnett – Ormen Lange
Nyhamna 420 kV
4 km > 300 MVA
Valhall HVDC Light
78 MW 290 km
Mariner option
Halul
Goliat
Dagny
Total Hild
55MW, 170km
Utsira (Statoil, Lundin)
300MW, 220km, HVDC
AC power transmission at low frequency or with
reactive compensation along cable
AC power transmission
HVDC power transmission
Cases
1. Large LNG facility with 5 trains each 5 MTPA, total of 25 MTPA
2. FLNG facility of 1,5 MTPA with direct drive or local power gen
3. An offshore platform with local power gen or power from shore
© ABB Group November 19, 2013 | Slide 25
Agree on Base Parameters
Characteristic Aeroderivate Gas Turbines Electric Drive
Weight and space Light unit but space and
weight consuming auxiliaries
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 (10s) Medium to quick (<1s)
Efficiency Narrow peak range High over wide range
Logistics Delivery time 3 years typ. Delivery 1-2 years system
HV AC/DC sea cable 3 years
Average operational efficiency of
system
25-38% 96% Drive
93-95% DC or AC Transmission
60-80% generation
Case 1: Large LNG plant:
Case 2: FLNG typical model
Case 3: Power from Shore
Summary
• More on-stream time
• Less fuel consumption - more product to sell
• Higher Stability - better Safety and Availability
• Reduced Maintenance
• AND Lower emissions
Slide 30
Why electrification? Energy Efficiency !
© ABB Group November 19, 2013 | Slide 31
ABB as a EICT Contractor for FPSO & FLNG
ABB as EICT Contractor
EICT, Lower Project Costs (>15%-20%)
¨Increased safety, reduced spurious downtime (10
days/yr)
Increased production (3-6%)
Reduced maintenance costs
Energy efficient production, reduced emissions
© ABB Group November 19, 2013 | Slide 32
