HIGH RELIABILITY AND FLEXIBILITY IN POWER GENERATION – DRESSER-RAND’S KG2 GAS TURBINE Drilling & CHP applications
Gas turbine generator sets
KG2 GAS TURBINE GENERATOR SETS
The legendary KG2 gas turbine was rst installed in 1972. Since then, close to 1,000 units have been installed in 62 countries worldwide, onshore and offshore, in continuous duty operations in all types of environments. The versatile gas turbine generator sets are used for a variety of base load and emergency power generation applications – from xed and oating installations offshore, to onshore oil elds, on rooftops, and integrated into buildings for simple cycle and combined heat and power (CHP) duties. With the acquisition of Kongsberg Dresser Power in 1985, Dresser-Rand became the original equipment manufacturer (OEM) of the well-proven and highly reliable KG2 product family. Since 1972, Dresser-Rand Norway Operations has developed and implemented a number of improvements and changes for the KG2 gas turbine. These improvements have increased its power output and efciency, as well as help control and lower emis -
sions. The product has proven itself in many installations, clocking more than 25 million operating hours with 99% availability. Some engines have been running more than 245,000 hours of continuous duty and achieved a lifetime of more than 30 years of run time.
KG2 gas turbine generator set at the Trans-Tunisian pipeline station in Korba, Tunisia.
Two KG2 gas turbine generator sets installed on the Dutch Unocal Helm platform. 2
© 2013 Dresser-Rand. All rights reserved.
Gas turbine generator sets
THE LATEST GENERATION OF KG2 GAS TURBINES
The newly released KG2-3G gas turbine is the third generation of this legendary product. It is based upon the same architecture as its earlier ratings, but is equipped with advanced fuel efciency and dry-low emission (DLE) combustion technologies to meet today’s evermore demanding emission regulations. While the turbine is still composed of the same proven engine parts (a compact rotor and a
single-stage radial compressor and turbine wheel), Dresser-Rand has rened the design and materials. With signicant improvements in the air-foil design, the efciency of the KG2-3G gas turbine has increased by 50% compared to the previous KG2 rating. This represents the highest efciency available for comparably sized gas turbine generator sets. The KG2-3G turbine’s four DLE combustors allow for operation below 24 ppm NO x and CO, without any catalytic exhaust remediation.
The KG2-3G gas turbine is designed to meet future efciency and emissions requirements.
We maintained the simplicity of the earlier KG2 models, while adding state-of-the-art turbine materials and combustion technology. This allows KG2 gas turbine users to operate their equipment with minimum maintenance and high availability. Maintenance intervals for the KG2-3G gas turbine are 8,000 hours between inspections and 40,000 hours between major overhauls.
© 2013 Dresser-Rand. All rights reserved.
The compressor and turbine sections are mounted back-to-back. The rotor assembly is cantilevered so that both rotor bearings are located in the cold end of the gas turbine. As there are no “hot” bearings in the KG2-3G gas turbine, the bearings are effectively designed without life limitation. The speed-reduction gearbox is an integral part of the gas turbine and reduces the output speed of the gas turbine to match the generator, while driving the lubrication system and liquid fuel pumps.
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Gas turbine generator sets
OUTSTANDING FUEL ACCEPTANCE AND OPERATIONAL BENEFITS
KG2 users benet from the turbine’s capability to accept a wide variety of fuels, ranging from pipeline quality natural gas to low heating value gas (e.g., well head or synthetic gas fuel with signi cant hydrogen content). With the capability of accepting fuel gas with 1.5% H 2S as standard (higher levels are subject to review), the KG2-3G gas turbine offers a reliable source of electrical power from associated gas otherwise ared at the well head.
KG2-3G gas turbine Technical data
Metric
• Requires a low fuel gas supply pressure of 12 bar for operation (and even lower pressure at start-up) • Allows for major load changes of up to 100% with insignicant change in generator frequency • Able to operate with a heat recovery unit to produce more than 6 tons of steam at 12 bar; operating the installation in CHP mode, overall efciency may exceed 90%.
Imperial
ISO (15°C/59°F) shaft output Output shaft speed
Additional operating benets include the following:
Metric
2,000 kW
Emission NOx (15% O2) CO (15% O2)
1,500/1,800 rpm
Fuel gas inlet pressure
Fuel type
Natural gas
Imperial
less than 24 ppm 10 ppm 12 barg
Generators
174 psig 400 V to 13.8 kV
Fuel rate
14,118 kj/kWh
13,381 btu/kWh
Weight, gas turbine/gear
1,800 kg
3,968 lbs
Exhaust gas temperature
577.3°C
1,071°F
Typical package weight
16,000 kg
35,300 lbs
Exhaust mas ow
9.4 kg/sec
20.7 lb/sec
Package dimensions (L x W x H) - approx.
13.7 x 4.5 x 6.9 m
40’ x 8.6” x 8’
The new KG2-3G gas turbine features highly c ompetitive technical data.
SFC – specic fuel consumption
EGT – exhaust gas temperature
Note – for operation below -40°C (-40°F), additional inlet and package heating is required.
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© 2013 Dresser-Rand. All rights reserved.
Gas turbine generator sets
KG2-3G GAS TURBINE FOR OIL AND GAS EXPLORATION APPLICATIONS
With its compact design and low weight, the KG2-3G gas turbine is ideally suited for both onshore and offshore drilling applications. KG2 gas turbines have an excellent block load capability, which means they can tolerate considerable load changes without having to go ofine. This was ex amined and proven by Esso’s Odin study in 1984; thereafter, the KG2 gas turbine was chosen for several drilling projects. The KG2-3G gas turbine has good weight to power ratio, and can operate on wellhead or are gas which offers signicant fuel cost savings to the operator. The turbine’s dual fuel capability with seamless changeover under load ensures continuous operation in the event of gas fuel curtailment. Thanks to its small footprint, a KG2-3G generator set can be easily integrated into an existing rig to cover additional power or heating demand. The package can be shipped without load permit which facilitates transport and handling. Our rugged package can also withstand transport along rough oileld roads.
Three KG2 gas turbine generator sets are running on dual fuel on the Doyon onshore drilling site in Alaska.
© 2013 Dresser-Rand. All rights reserved.
A view of Esso’s Odin platform, where three KG2 gas turbine generator packages are installed. These gas turbines were selected in part for their excellent block load capability.
Four KG2 gas turbine generator sets deliver power to a Dubai Petroleum Company platform.
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Gas turbine generator sets
KG2-3G GAS TURBINE FOR COMBINED HEAT AND POWER APPLICATIONS
Cogeneration or combined heat and power (CHP) is another suitable application for the versatile KG2-3G gas turbine. CHP systems facilitate electricity production and provide useful heat at very high efciency. By locating a power generation system at the heart of a facility or process it is possible to capture the heat (usually a wasted byproduct of electricity generation). The KG2 cogeneration system combines the KG2-3G gas turbine with a pre-engineered steam heat recovery package. The system provides a continuous base load supply of both electricity and steam, while lowering energy costs and CO 2 emissions. With a wide range of steam pressure congurations, this sys tem can be matched to almost any process need.
CHP 2000 system output
Metric
Imperial
Electric output
1,950 kWe
2,615 hp
Electric generator frequency
50/60 Hz
50/60 Hz
Steam output at 10 bar (145 psi)
7.5 t/h
16.5 klb/hr
Chilling at 37/30°C (98.6/86°F)
5.5 MW
7,375 hp
Hot water from 10-80°C (50-176°F)
16kg/sec
35 lbs/sec
CHP output choices:
Packaged CHP systems deliver the maximum possible energy cost savings when deployed in applications where the electrical and thermal outputs of the system can be consumed at all times by the host facility. The standard CHP 2000 system delivers high-quality steam for heating purposes. Alternatively, the exhaust energy can be used for chilling and delivers approximately 5.5 MW of chilling power. A balance of both is also possible, as well as the possibility of extracting hot water from the lubricant oil cooler. Adding a steam condenser can boost the total efciency of the gas turbine to the mid-90% range. Dresser-Rand CHP systems can be designed to meet a wide range of application-specic requirements. 6
The KG2 gas turbines at the McKittrick enhanced oil recovery site in California, USA , generate steam that is injected into the oil well to facilitate the oil ow.
Energy consumers demand high efciency and re liability in order to minimize operating costs and maximize uptime. KG2-3G CHP systems are sup plied as comprehensive, factory-tested packages that can be easily integrated into existing site op erations. Items such as synchronizing switchgear, heat recovery equipment, emissions treatment, attenuation, and lube oil systems are included “within the box.” This dramatically reduces the risk of cost overruns and performance issues associated with traditional “site-built” systems.
CHP 2000 package data
LTHW ow temperature
82.2°C/180°F
LTHW return temperature
71.1°C/160°F
Noise dB(A) at 25’
<75
GPM of hot water (20°F delta T)
520
CHP 2000 dimension data
Metric
Imperial
Length
12.192 m
40 ft
Height
2.438 m
8 ft
Height
2.591 m
8 ft 6 in
Weight
17.2 t
38,000 lbs
© 2013 Dresser-Rand. All rights reserved.
Gas turbine generator sets
KG2-3G GAS TURBINE– A RELIABLE ASSET FOR POWER GENERATION
Dresser-Rand’s long standing experience with installations for a large variety of applications, combined with the KG2-3G gas turbine’s competitive technical features, make these gas turbine packages an ideal solution for the oil and gas and energy markets. Dresser-Rand’s KG2-3G gas turbine … • offers an upgraded version of the well-proven KG2 gas turbine. • operates on gaseous and liquid fuels. • accepts a wide fuel range which includes wellhead gas and sour gas with a signicant H2S content. • is an excellent solution for recovering are gas for energy production. • has a dr y low emission combustion system for NOx and CO to 24 ppmv at 15% O 2 over a wide operating range. • allows for excellent heat recovery in CHP applications. • can operate at extremely low temperatures (as low as -60°C/-76°F). • is designed to operate for 40,000 hours between major overhauls (and one annual visual inspection). • is designed for easy maintenance at low ambient temperatures. • is small and light-weight, built for non-permit shipping loads. • allows for local and remote monitoring and operation, and is also suitable for installations with limited access.
With its rugged steel base frame design, its compact dimensions and low weight, the KG2 gas turbine generator set allows for easy on-site maintenance, as well as simple transport to other locations.
Dresser-Rand’s KG2-3G gas turbine generator packages are delivered completely factory tested. We offer OEM service for operation and maintenance for all our KG2 installations.
Three KG2 gas turbine packages installed on Shell Malay sia’s SSB drilling platform. © 2013 Dresser-Rand. All rights reserved.
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This document comprises a general overview of the products described herein. It is solely for informational purposes, does not represent a warranty or guarantee of the information contained herein, and is not to be construed as an offer to sell or a solicitation to buy. Contact Dresser-Rand for detailed design and engineering information suitable to your specic applications. DresserRand reserves the right to modify its products and related product information at any time without prior notice.
