KG2

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 efciency, 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 efciency 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 rened the design and materials. With signicant improvements in the air-foil design, the efciency of the KG2-3G gas turbine has increased by 50% compared to the previous KG2 rating. This represents the highest efciency 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 efciency 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 benet 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 insignicant 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 efciency may exceed 90%.

Imperial

ISO (15°C/59°F) shaft output Output shaft speed

Additional operating benets 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 – specic 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 ofine. 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 signicant 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 oileld 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 efciency. 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 congurations, 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 efciency of the gas turbine to the mid-90% range. Dresser-Rand CHP systems can be designed to meet a wide range of application-specic 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 efciency 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’