Lars Torstveit, ABB AS ABB Capabilities for ... · PDF fileABB Capabilities for Electrification within Oil, Gas & Petrochemicals. Main Electrical ... HV/MV Switchgears/MCC ... Machines

© ABB Group September 24, 2009 | Slide 1

ABB Capabilities for Electrification within Oil, Gas & PetrochemicalsMain Electrical Contractor (MEC)

Lars Torstveit, ABB AS

Agenda

Joint session8:00 - 8:158:15 - 9:30

Separate sessions Eletrification Automation & Safety Telecom

9:30 - 10:30 Introduction to ABB as a System Integrator

10:30 - 10:45

10:45 - 11:45 Main Electrical Contractor (MEC) -Total System Integration

Main Automation Contractor (MAC) - Total System Integration Support for Remote Operation

11:45-12:45 Peregrino project - Example of MEC Case studies: Challenges/Solutions DWDM, fiber optics high speed

communication12:45 - 14:00

14:00-15:00 Dry type transformers - Ideal for FPSOs

Automation & Safety System - Life Cycle Simulator Total FPSO networking

15:00 - 15:15

15:15-16:00 MV & LV switchgear solutions for FPSOs

Integratede Systems - Topside, Marine, Remote: Integrated

OperationRadio Switch Tetra, digital radio

16:00-17:00ABB Relion - Intelligent protection solutions integration with ICSS -

IEC61850 and ProfinetAdvanced Control / Services Integrated operations and

Integration towards Automation

17:00-17:30

Welcome and general introduction to the workshopABB introduction of company and O&G Division, FPSO reference anda ABB plans for the Offshore Market

Power Management System

Discussion

Coffe Break

Lunch

Coffe Break

Eventos na Sala 1 (404) Sala 1 - 61 pessoasEventos na Sala 2 (408) Sala 2 - 30 pessoasEventos na Sala 3 (411) Sala 3 - 30 pessoas

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Agenda

Introduction to COE ElectrificationMEC concept Large Drives Subsea Drives Power From shore Packages Drilling DrivesAdditional Technologies

Power ManagementCondition Monitoring

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Application Areas for Electrification

ACHVDC

HVDC

ACHVDC

AC

Power from shore

Offshore Power Distribution

FPSO e-house solutions

Subsea drives solutions

Large Drives solutions

Packaged Drilling Drives

Onshore Power Distribution

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ABB oil and gas centers around the world

Toronto

ClevelandBeijing

TokyoCairo

Mexico City

BangkokBangalore

Caracas

Sao Paulo

Sydney

Riyadh Abu Dabi

Singapore

Copenhagen

Azerbaijan

Bogota

Houston

BrusselsMannheim

WarsawAmsterdam

ShanghaiTehranKuwait

Kazakhstan

Angola

Nigeria

Moscow

LibyaAlgeria

Calgary

Buenos AiresJohannesburg

Bartlesville

LondonParis

Madrid

Oslo

MilanoIstanbul

Centers with Electrification activeties

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Key capabilities Center of Excellence Electrification for Oil & Gas

Concept System study group Analysis and simulation during FEED and execution

Total life cycle solutionsCondition Monitoring and Remote operation

Packaged SolutionsE-HousesEngineered Drives Packages

Power Management Systems & Electrical ControlVital part of pursuing MEC system projects

Single interface between ABB and customerInternationally Certified Project Managers

Capable of Overall System ResponsibilitySolid project execution dedicated to O&G market, standards and applicationsStrong After Sales and Service Organization

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What is an Electrical & Drive System?

Equipment/Products:

Generators, HV/MV Switchgears/MCC’s, LV Switchgears & MCC’s, Machines and Motors, Frequency Converters, Transformers, Filters, etc.

Services: From Product to Integrated SystemSystem Design Criteria, Studies/Analyzis & Calculations,Project Management, Engineering, Documentation (Product, Project, DFO),QA/QC, HES, Testing, Commissioning, Training, After Sales Support.

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LV DistributionIndustrial

400/230V

MEC - Typical Integrated Electrical System

HV Motors

132/66kV

22kV

11kV

LV Motors

Power Transformers

400kV

HV Outdoor Switchgears

Indoor HV GIS

Indoor AIS

Indoor GIS

Ex

LV DrivesLV Distribution

Transformers

Power Transformers

Power Transformers

Battery UPS

HV Drives

LCIDrives

690V

Distribution Transformers

LV Switchboards

>20kVMotorformer

Turbines & Generators

Generator Transformers

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400/230V

MEC - FPSO - Integrated Electrical System

Generator

HV

LV Motors

Indoor GIS

Ex

LV Drives

LV Distribution Transformers

Battery UPS

HV Drives

•Compressors

•ESP

•Water injection

•Etc

LV


LV Switchboards

Generator

Indoor AIS

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Motivation for MEC - The Hard Part: Hidden Costs

Equipment Costs Price Engineering Costs

Construction Costs Inspection & Testing

Performance Problems Safety Costs Customer Dissatisfaction Spare Parts

Duplication of Effort Debugging Costs

Air Freight Liability Costs Expediting Shipments

Scrap

Late Delivery Costs Overtime Startup Delays

Equipment Service Calls Maintenance Costs Energy Costs

Equipment Shutdown Costs High Inventory Costs

Construction Rework Maintenance Costs Toxic Emissions Training Costs Environmental Regulations Stress

Ease of Repair Engineering Changes Frustration

Paperwork Inspection Dissatisfaction Stocks

Rescheduling

HIDDEN COSTS

KNOWN COSTS

Interface Problems

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Key values of the MEC concept…

Risk management

Lower procurement cost

Lower project cycle costs

Lower training costs

Lower life cycle support costs

…to provide the lowest total project cost

Integrated technology

Common solutions

Single source for documentation

Greater operability

Ease of life cycle maintenance

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Early involvement through strategic partnershipEnables ABB’s full range of experience and ability to draw upon existing and proven solutions.

This Continuity and migration of knowledge optimises the design and improves project performance

The MEC concept;Reduces Commissioning & Installation riskCost & Time

Because ABB takes responsibility for a complete and integrated systems delivery

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Value Added

Total Cost = Cost of Purchase + Cost of Project Execution

Lack of competition Interface Issues

Cost of Project ExecutionEPC’s hours spent on admin & engineering

Variations

Integration Testing

Installation, Commissioning, Hand-over

Penalties / Incentives

Balancing the risk

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Both parties should benefit from this MEC concept

Creating win-win situations within;Competence development

Technical development

Administrative systems and routines

General information exchange and more efficient relationship

Improved Safety – a single team of installation and commissioning engineers reduces the number of incidents

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Can MEC reduce my project CAPEX cost ?

100 %

80 %

Early involvement, standardisation, improved work processes and tools

Elimination enquiry, bidding and negotiation, reduced sales & Admin.

Increased productivitylower prices

Trusted performance on-time delivery

Standardisation and reuse

Reduce spare parts and training

Examples of cost saving potentials

EngineeringProcurement

Product costs

Expeditinginspection

Documentation

Commissioning, start up, training

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Can MEC reduce my project schedule ?

0 12 months

MEC

Traditional

g Commercial g Designg Manufacturingg Preparationg Installationg Commissioning

Example of schedule reduction

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Multiple Electrical Package Suppliers

1 of 2

R&C = Risk & Contingencies

Material

Admin

Engineering

Material

Admin

Engineering

Material

Admin

Engineering

Material

Admin

Engineering

Material

Admin

Engineering

Engineering

R&C

Admin

Engineering

R&C

Admin

Engineering

R&C

Admin

Engineering

R&C

Admin

Engineering

R&C

Admin

MEC Coordination

Pool of multiple suppliers

Project Management

Other Packages

Other Packages

Removing non-value add

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Main Electrical Contractor / Electrical System Supplier

2 of 2

R&C = Risk & Contingencies

MEC

Engineering

(R&C)

Admin

MEC Coordination

(R&C)

Material

Engineering

Material

Engineering

Material

Engineering

Material

Engineering

Material

Engineering

Project Management

Other Packages

Other Packages

Admin

Removing non-value add

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MEC Integrated Deliveries - Value Pyramid

PRODUCT

Service

Operations capabilities

Functionality. Performance

LIFE CYCLE

Project Execution

System functionality & performance

Quality, price for several products from one supplier

SYSTEM

BUNDLING

Quality and price for single products

Degre

e of I

nteg

ratio

n

ABB has experienced that increased degree of integration will decrease total project costs.

Cost (

Capex

+ Ope

x)

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Business Process – Early Involvement

Product suppliers responds to RFQ here

System approachearly start

FeasibilityConcept

Market Shift to system approach

Pre Feed FeedBasic/

Detailed Design/FAT

Installation/Comissioning

Start-up Operation

All Electricdecision

Products and services

MEC decision

The most critical decisions are made early

Secure best information for optimal decisions

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Technical concept study group

What can ABB offer with a concept study group?ABB can take the lead/participate in network planning at an early stage in a project.ABB can take the lead/participate in establishing design criteria and operational philosophyABB can hold the title to system responsibility with regard to the electrical power system

ABB’s strong points with regard to studies:Close relationship with equipment factoriesEasy access to all product informationInformation on ongoing development projects within ABBLong experience in calculations and product deliverables

Result:Optimised power system design and component ratingsCompletion of power system analysis during project phaseIncreased added value in system deliveriesReduced technical and financial risks for the client

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Technical concept study group Technical focus areas

Technical focus areas:Systems:

Complete electrical power systemsLong AC transmission systems (electrification)HVDC light systemsMV and LV voltage drive systemsLong step-out systems

Studies:Feasibility studiesDynamical simulations/analysisShort circuit calculationsLoad flow analysisHarmonic analysis (VSD, LCI, filter)Motor start analysisTransient stability studiesProtective device coordination studiesVoltage drop calculationsVoltage surge evaluations

Calculations can give input to:Operational philosophies:

Operation of generatorsNetwork configuration (ring/radial, interlocks)Protection philosophyPower management system

Equipment rating:Switchboard rating (IN, Ik”)Transformer rating (S, ux)Power cables cross-sectionNeutral earth resistorCT/VTsRelay settings

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Our tools

Electrical power systems : Non-linear functions, saturation, frequency dependencies….Requires dedicated tools for calculation

PTW NEPLAN EDSA MATLAB/ SIMULINK SIMSEN ATP

Loadflow X X X X

Short circuit X X X X

Motor start X X X X

Dynamic simulations X X X

Relay coordination X X X

Harmonic calcs X X X X

Transient simulations X X

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Structure for Project Execution and Management

Screenshot of Work Process for Project Execution

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Project Execution - Typical Organisation

Client

Project Manager

Project Steering

Committee

Lead Engineer

Quality

HES

Document

Control

Planning

Purchasing

Cost

Control

Coordination, Studies, etc

Supplier

/ Manufacturer

Package

Responsible

Package

Responsible

Supplier

/ Manufacturer

Install

+ CommPreparation

Site

Coord. / Management

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Engineering (cont.)

System Design Coordination

BasicEngineering

Client

Primary

Documentation

*)

Supplier

Documentation

Client

Supplier

Supplier

(Package) Design Verification

Client

Feedback on

Documentation

Feedback to Supplier

on

Documentation

Basic Engineering

Review

Technical

Requisition4.2 Basic Engineering and Review

4.5 Detail Engineering

4.1 Design Basis4.3 Technical

Requisitions

for Procurement

4.4 Queries

DocumentControl

*) Such as:-

Document list- Single Line diagram- GA drw- Foundation drw- Vital Interface info- Input for system studies- Cable schedule- Revised Prod. Plan

DocumentControl

DocumentControl

DocumentControl

Establish

Project Standards and Guidelines

Produce

Primary

Documentation

Internal

Primary

Documentation

**)

**) Such as:- Dimensioning Studies- Calculations and Curves- Function Descriptions- Interface Records- Document Lists- Internal Requirements / Descriptions

MOM / Report

Basic Engineering

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400/230V

MEC - FPSO - Integrated Electrical System

Generator

HV

LV Motors

Indoor GIS

Ex

LV Drives

LV Distribution Transformers

Battery UPS

HV Drives

•Compressors

•ESP

•Water injection

•Etc

LV


LV Switchboards

Generator

Indoor AIS

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Agenda

ABB Electrical products portfolioFPSO offeringsLarge Drives Subsea Drives Power From shore Packages Drilling DrivesAdditional Technologies


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Statoil - Troll - VSD system for export Gas Compressors

5 x Megadrive LCI system5 x 41MW /48MW motors (EExp)132 kV TransformersFilters units and reactors12 pulse circuit systemSynchronous machine with brushless exitationWater cooled

1 x LCI Drive and 41MW motor delivered in 2006

Export Gas capacity upgraded to 146,5 mill Sm3/Day

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Very large Variable Speed Drives Systems (VSDS)

Largest Oil&Gas VSDS (Ormen Lange):3 x 48 MW export compressor2 x 7,5 MW Recompression

Up to 100 MW possible (NASA windtunnel)Applications:

LNG plants (cryogenic)Gas Plants (turbo expanders, export)RecompressionRe-InjectionOffshore in combination with HVDC light

Issues:EmissionsMaintenanceFlexibility, control.

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Ormen Lange / Back-to-Back

Back-to-back test setupBackground: Two LCI convertersForeground: Synchronous motor and generator coupled

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Back-to-back test setupView of two transformers

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Filter-components in the cellar

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Agenda

ABB Electrical products portfolioFPSO offerings Large DrivesSubsea Drives Power From shore Packaged Drilling DrivesAdditional Technologies


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Electrical subsea aplication equipmentABB

Transformers

Converters

Switchgear components (Vetco/ABB) - prototype

SEPDIS Subsea Electrical Power Drives Framo/Vetco/ABB)- prototype

System Studies

Aplication Control Software

OthersSubsea motors

Electrical connectors

Umbilical

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Reference Project: Tyrihans SRSWIRAW SEAWATER INJECTIONSUBSEA PUMP INSTALLATION

GA

S IN

JEC

TIO

N

UM

BIL

ICA

L

TYR

IHA

NS

PRO

DU

CTI

ON

FLO

WLI

NE

ELEC

TRIC

PO

WER

STA

TUS/

CO

NTR

OL

SIG

NA

LS

KRISTIN ÅSG.B

WATERINJECTION PUMP

P

TYRIH.

FIGURE 3

WATERINJECTION

SEAWATERINTAKE

TELECOM LINK

Field Operator: Statoil

Application: Subsea Raw Sea Water Injection

Capacity: 14 000 m3 untreated seawater/day

Pump Qty: 2

Tie-in distance: 31 km

Host platform: Kristin

Pump vendor: Aker Kvaerner Subsea

Project completion: 2009/2011

The project will add production worth > 1000 MUSD

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Reference Project: Tyrihans SRSWIABB Scope of Supply• 2 x Topside VSD System

• ACS1000 Water cooled converters

• Oil filled step-down/up transformers

•2 x Subsea Transformer

• 4000 kVA

• Insulation monitoring system on pump side

• Insulation monitoring system on umbilical

• System Design Report

• Time domain simulations

• Breakaway torque calculations

• Loadflow calculation

• Fault analysis

• THD calculations

-2000-1500-1000-500

0500

10001500

-1000-500

0

5001000

-10000-5000

0

500010000

0.00 0.05 0.10 0.15 0.20

Ceiba C4 Commissioning tests - 75 Hz 820 A

I3 aft

er si

ne fil

ter A

N-C4

_021

.csv

( A)

U1-U

3 afte

r sine

filter

AB-

C4_0

21.c

( V)

U3-G

ND af

ter st

ep-u

p tra

nsfor

mer

AN

( V)

Time ( s)

I3 after sine filter U1-U3 after sine filter

U3-GND after step-up transformer

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Åsgard MF Project VSD & Long Step-out Power qualification

M

Sine filter

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Scope of supply for Åsgård long step-out qualification program

Equipment deliveriesQualification testsSimulationsInstallationCommissioningTesting

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Equipment deliveriesStep Up transformer

15 MVA, 6,6/36 kVTapingsWater cooled

Step Down transformer15 MVA, 30/6,2 kVTapingsSubsea (will be run with a water cooler at Kårstø)

Cable simulatorSimulate the 47 km cable52 kV voltage10 phi equivalent modelExist of resistance, inductance, capacitance, breakers

Measurement systemCustom sensors (voltage/current for high voltage, variable frequency and high band with)Data Acquisition system, by National Instruments Software for displaying and processing and saving data

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Installation of Cable simulator

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Main Technical challenges for ABBWorld longest umbilical cable length connected to topside frequency converter output (47km)Biggest power rating for step-out system so far (rated for 6-8MW compressor power)Highest supply frequency performed on long step-out systemQualifying and building step-up and sub-sea transformer for rating up to 15MVA and supply frequencies up to 200Hz

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SimulationSteady state calculation

Loadflow / voltage drop at different operating pointsStart analysis

Dynamical simulationLoad variationsHarmonics during steady state operationTrip analysis

Done for:189 Hz Compressor159 Hz Compressor102 Hz Compressor400 kW Pump

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System design

Dynamical simulations performed in time domainSoftware (Matlab/simulink)Dynamical model of the complete system including converter, topside transformer, cable, subsea transformer and motorModel of mechanical load The following analysis can be performed by ABB

Motor starting with specified break-away torqueTransient load variations Different operation pointsTrip analysis

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Testing at KårstøRun the compressor with and without the long step out system

Compressors with different speed6000 rpm (102 Hz)9500 rpm (159 Hz)11200 rpm (189 Hz)

Different voltage levels on the cableBoth transformers have tapings

Different cable cross-sectionLoad variations on the compressor

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Why testNever been delivered such system (length and power)Qualified the overall electrical system

Converter and softwareTransformer designCableMotor

Get experience with such systemCompare simulation and test measurement

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Ormen Lange – Subsea TransformerPilot Subsea Transformer

20 MVA

132kV / 22kV

Single shell

132kV connector is new technology (Vetco)

Subsea Transformer70 MVA

132kV / 22kV

Single shell

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Agenda

ABB Electrical products portfolioFPSO offerings Large Drives Subsea DrivesPower From shore Packages Drilling DrivesAdditional Technologies


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Why Power From ShoreAvoiding emissions !

25 % of Norway CO2 emissions comes from offshoreSignificant contribution to fulfill Kyoto

protocol if the best projects is electrified

Operational and maintenanceSignificant lower OPEX then Gas turbine, CAPEX project dependentFacilitates remote operations, key trend in the offshore industry

Health Safety and Environmental impact

No gas turbines will reduce riskLess helicopter transport

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Submarine cables

Troll A platform station Kollsnes

land station

Norway Sweden

UK

Troll-A Power From Shore: World’s 1st Offshore HVDC system

Statoil’s Troll A Pre-compression projectKey platform data:

Troll A delivers gas to Kollsnes

from all Troll field platforms

Total weight: 678 500 tones

Height: 472 m (approx. 120 m above sea level)

Current gas processing capacity:

100 million m3 per day

Reservoir pressure declines – pre-compression is needed

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Troll VSD – Lifting of module

Approx 700 tones

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Valhall HVDC Light Power From ShoreBP’s Valhall Platform Redevelopment project

Valhall

Lista

New PH platformNew PH platform Existing WIPExisting WIP

Status:Feasibility and pre-engineering studies between 2003-2005 were successful, leading to Valhallfield partners deciding in April 05 to take power from shore as main option

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Gjøa Power from Shore

Power available at Mongstadrefinery

Double supply lines from national grid

Sub Sea Cable

Shore

Supply

11kVTransformer

Sub seaOnshore Offshore

Transformer132kV

90kV AC

90km

Gjøa

Kvitebjørn

Camilla&Belinda

ValemonHuldra

Hild TrollOseberg

TampenGjøa

Kvitebjørn

Camilla&Belinda

ValemonHuldra

Hild Troll

Langeled

Tampen

Oseberg

ÅTS

Gjøa

Kvitebjørn

Camilla&Belinda

ValemonHuldra

Hild TrollOseberg

TampenGjøa

Kvitebjørn

Camilla&Belinda

ValemonHuldra

Hild Troll

Langeled

Tampen

Oseberg

ÅTS

Florø

Mongstad

StureKollsnes

Vega

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Gjøa Electrification - Overview©

ABB

AS

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. 200

8

90kV Subsea Cable

90kV Offshore Cable

4.5MW VSD type ACS 1000

145kV Gas Insulated Switchgear

17.3MW & 11.1MW VSDs type ACS 5000

12kV Gas Insulated Switchgear

18MW 90/11kV Offshore Power Transformers

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Agenda

ABB Electrical products portfolioFPSO offerings Large Drives Subsea Drives Power From shorePackaged Drilling DrivesAdditional Technologies


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AC Drilling Drive System - Overview

DRAWWORK W/4 AC MOTORS

THREE WINDING TRANSFORMER

MUDPUMPS WITH AC MOTORS

TOP DRIVE DRILLINGMACHINE WITH AC MOTORS

CONVERTER PANELS DRILLING AND WINCH DRIVES

ACS/DCS 600MarineDrives

ANCHOR WINCH WITH AC MOTOR

HIGH VOLTAGE SWITCHBOARDS

DIESEL ENGINES/ GENERATORS

VESSEL AUTOMATION POWER MANAGEMENT

ALARM AND MONITORING

LOCAL CONSOLE FOR MUDPUMPS

REMOTE I/O PANEL

REMOTE I/O PANEL

DRILLERS CABIN MAIN CONSOLE

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EDP Engineered Drives Products

•Try to get most of our deliveries as a Plug & Play delivery•Get more of ABB`s assortment into one delivery•To help customers to get a complete tested and working product•Capabilities is good due to large group of system engineers•Engineers are used to handle several systems into one delivery•Achievements•50 Containers systems to Aker, 6 large E houses for drilling to Ability

Packaged Drilling E- House

Strategy, Capabilities and Achievements

•For new build and retrofit concepts•Plug and play solutions•Electrical systems– generation, distribution and AC / DC drives•Life cycle support, and total package responsibility.•Standardized communication interfaces

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Agenda

ABB Electrical products portfolioFPSO offerings Large Drives Subsea Drives Power From shore Packages Drilling DrivesAdd-on Technologies


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Electrical & Vibration CM – Portfolio todayDrive

MonitorMedium Voltage

Monitor

Transformer Monitor High Voltage

Monitoring

Low Voltage Monitor

Sea cable Monitor

Vibration Monitor

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Our motivation factor

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Documents

Lars Torstveit, ABB AS ABB Capabilities for ... · PDF fileABB Capabilities for Electrification within Oil, Gas & Petrochemicals. Main Electrical ... HV/MV Switchgears/MCC ... Machines