caterpillar driver comparisons 03022012

7/23/2019 Caterpillar Driver Comparisons 03022012

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A comparison between reciprocating

engines, turbines, and electric motors

Drivers for Gas

Compression

Presented byWayne Longer


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Compressor station design 73,000 horse-power 42 pipeline

Courtesy of


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4/62Exhaust-Catalyst-Air intake-Engine coolers-Gas coolers-Separators

Courtesy of


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How does the air flow ?

rte

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Working space overhead bridge crane - ventalation


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Note the insulation on the exhaust systemsCourtesy of


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How Does an Engineer Decide?Factors and Examples

Company

ABCProject


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Factors for Deciding Driver & Compressor

Site information environmental issues

operating conditions

pressure ratios

volume of gas variability of operation

Owning and operating costs

initial capital expenditure

fuel/electricity costs

maintenance

What driver is familiar

like to go with what you know Risk assessment

driver reliability - storm outage?

redundancy of units crank failure? mix of driver types


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Driver Options


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Driver OptionsReciprocating Engines

Major players

Caterpillar

Waukesha

Wrtsil

Typical engine power

1200 - 8000 bhp

Operate at 750 - 1000 rpm

CAT G16CM34

CAT G3612

Waukesha ATGL16V


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Driver OptionsTurbines Major players

Solar

Siemens

Elliot GE

Rolls-Royce

MAN Turbo

Typical power 1500 - 30,000 bhp

Operate at 11,000 - 23,000 rpm

Solar Mars 90

GE10-1

GE10-2


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Driver OptionsElectric Motors

Major players

Toshiba Siemens

Rockwell (formerly Reliance)

Ideal GE

ABB

Typical power 1300 - 20,000 bhp Operate typically at 300 - 3600 rpm

high speed motors at 12,000 - 23,000 rpm

Siemens

H-Compact PLUS

Siemens

H-Compact

Direct Drive Systems

Frame 2 (high speed motor)


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Compressor Options


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Compressor OptionsReciprocating

Major players

Ariel Dresser-Rand

Cameron Compression

GE

300 - 1800 rpm input speed

Wide operating range 1 to 10,000 PSI

Advantage at higher pressure ratios, > 3:1

Ariel JGV/6

Dresser-Rand HOS

Cameron Axis


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Compressor OptionsCentrifugal

Major players

Solar

Dresser-Rand

Siemens

Rolls Royce

Operates with higher speed drivers (motorsand turbines)

Sweet spot at low pressure ratios and highvolumes < 1.4 pressure ratio is ideal

Operate best at lower discharge pressures < 2000 psi

Siemens STC-SV

Dresser-Rand

Datum

Solar C16


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Package Combinations


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Package CombinationsReciprocating Compressor

Electric MotorRecip Engine


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Package CombinationsCentrifugal Compressor

Electric MotorTurbine


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Emerging TechnologyDual Drive

Engine or Electric motor driver

Flexibility lowest cost by the hour

Reduced emissions


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Performance Characteristics

Fuel and Power*

Compression Efficiency

(Turndown Flexible operation)De-ration

Emissions

Noise

* For the following comparison tables, cost of electricity is based solely on cents/kWhr price; demandcharges not included and could substantially increase yearly energy cost


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Electricity Source: Energy Information Administration


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Fuel and Power4700 - 5500 bhp*

($4.00/MMBtu and 6.5 cents/kWhr at 8000 hours/year)

$2,211,040

(.0502)

425296.5%18005500Toshiba/

Siemens

$1,020,638(.0269)

673639%10004735G3616

$1,372,400(.0366)912527.9%15,0004700Gas Turbine

$1,495,120(.0339)

849529.6%13,6005500501 KC-5

$2,132,565(.0497)

410197.5%70005360DDS Frame 8

bhp rpmEngine

Turbines

Motors

Btu/bhp-hr

or kW

$/year

($/hp-hr)Efficiency

* Ratings based on companies published ISO conditions

Demand charges not included and could substantially increase yearly electric costs


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Fuel and Power7700 - 10,400 bhp*

($4.00/MMBtu and 6.5 cents/kWhr at 8000 hours/year)

$1,735,119

(.0232)

579344.3%7509360Wrtsil

16V34SG

$4,019,896(.0502)

7730kwk96.5%180010,000Toshiba/Siemens

$1,559,827(.0238)

595942.7%7508180G16CM34

$1,961,344(.0318)

796032%15,0007700Gas Turbine

$2,469,121(.02993)748434%15,20010,310Gas Turbine

bhp rpm

Engines

Turbines

Motor

Btu/bhp-hror kW

$/year($/hp-hr)Efficiency

Ratings based on companies published ISO conditions @ 70F Turbines de-rate as temp increases

Demand charges not included and could substantially increase yearly electric costs.


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True Carbon foot print ???

Combined cycle


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Additional Electric Power Costs

Demand charges

based on total at site power no charge if electricity is not used

even 1 kW of usage triggers total kW demand charge

can be firm or interruptible

firm is more expensive

usually between $5 - $8 per kW in one month

some companies charge per kW-hr

$.009/kW-hr is common

$291,000$6.505000 bhp =3731 kW

YearlyDemandCharge

DemandCharge

($/kW-Mo)

ElectricMotor Power


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Compression Efficiency

Reciprocating compressor

typically run at 70% - 85% efficiency suited for higher pressure ratios >1.4:1 ratios

Centrifugal

typically run at 70% - 85% efficiency

highest efficiencies at lower pressure ratios 1.2:1

high pressure ratios favor reciprocating compressors

low pressure ratios favor centrifugal compressors


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Horsepower De-rate

Ambient TemperatureAltitude

Fuel gas

Site specific ???


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G16CM34 and Taurus 60Available Power

5500

6000

6500

7000

7500

8000

8500

9000

0 10 20 30 40 50 60 70 80 90 100

Temp, degF

Power,bhp

G16CM34

Taurus 60 (ISO)

Taurus 60 (500 ft)

Taurus 60 (1500 ft)

G16CM34

Turbine - Sea level

Turbine - 500 ft

Turbine - 1500 ft

Turbine


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Fuel Consumption at Sea Level

6000

6500

7000

7500

8000

8500

9000

9500

10000

10 20 30 40 50 60 70 80 90 100

Ambient Temp (deg F)

Fu

elConsumption(btu/bhp

-hr)

G3616 Centaur 50Recip Turbine


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De-rate - Electric Motor

Ambient Temperature

Insulation usually enough to avoid de-rationAltitude

Typical motor will not de-rate until 3500 ft.

Above 3500 ft. requires special insulation - cooler possible derating (though not as severe as engines and turbines)

Load change

Turndown does not affect motor efficiency much .


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Emissions(g/bhp-hr) w/o after treatment (Oxidation Catalyst 90% reduction)

Electric Motor

At site only from packaging leaks (valves, vents) Transfers emissions to power plant - Carbon foot print??

6.02.00.9Wrtsil16V34SG

0.20.60.2 - 0.6Turbine

6.0 - 7.02.00.5 0.7GCM34

6.02.50.5 - 0.7G3600

THCCONOx


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Noise Comparison

Reciprocating Engine

128 dBA

noise dampening required in some areas

Turbine

82 dBA

high frequency noise

dissipates quickly with distance

Electric Motor

70 dBA

considered noiseless if inside building

Exception - air flow for cooling and gas flow in pipe


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Packaging andInstallation Comparison


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Packaging and InstallationG3600

Air inlet system

Exhaust system

Cooling system

Packagecontrols/electronics

Recip compressor

Scrubbers Pulsation bottles

Gas cooler


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Packaging and InstallationG3616

116 223

Package approx

weight: 95,000 lbs G3616:65,900 lbs

Compressor:

28,600 lbs Package approx

length:

29 feet Package approx

width:

178 inches

Package approx height: 137 inchesNote: does not include auxiliary modules, additional piping


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Packaging andInstallation - GCM34

Air inlet system

Exhaust system Fuel Module

Combined Module

Unit Control Panel

Recip compressor

Scrubbers Pulsation bottles

Gas cooler


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Package approx weight:

300,000 lbs G16CM34: 179,080 lbs Compressor: 120,000 lbs

Package approx length:42 feet

Package approx width:

220 inches Package approx height:

137 inches185

319

Packaging andInstallation - G16CM34

Note: does not include auxiliary modules,building/infrastructure or additional piping


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Packaging and InstallationTurbine

Air inlet system

Exhaust system

Cooling systemPackage controls

Rotating compressor

ScrubbersGas cooler


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Packaging and InstallationTurbine (6000 hp)CENTRIFUGAL

COMPRESSOR

COOLING SYSTEM

(off skid)


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Packaging and InstallationElectric Motor with Reciprocating Compressor

Air ducting

Cooling System

Package controls

Recip compressor Scrubbers

Pulsation bottles

Gas cooler

Typical motor weight: 20,000 lbs +/- 5000

Typical motor length: 75 +/- 25 4 throw compressor 116


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Packaging and InstallationElectric Motor with Centrifugal Compressor

Air ducting

Cooling System

Package controls/electronics

Couplings

Gear box or transmission

Centrifugal compressor


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Packaging and InstallationElectric Motor with Centrifugal Compressor

Typical motor weight: 20,000 lbs +/- 5000

Typical motor length: 75 +/- 25

Other package dimensions similar to turbine

addition of gear box or transmission could greatly increase length


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Packaging and InstallationAdditional Requirements

Reciprocating Engines and Turbines

Usually need enclosure

Possible noise suppression and exhaust

after treatment

Similar installation for both drivers


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Packaging and InstallationAdditional Requirements

Electric Motor

Building / enclosure needed

Sub-station

includes switchgear, breaker, transformers, drives

Need VFD or transmission for variable speed

Need transmission lines

Could take a years or more to get power tocompression station (Eagleford shale)

Right-away procurement


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Lifetime Maintenance Compared(includes labor at $100/hour and oil at $7.40/gallon)

Reciprocating engines

G3600 avg. ~ $0.0036/bhp-hr

GCM ~ $0.0037/bhp-hr

Downtime over 15 years

G3600 800 hours CM 730 hours

Gas turbines

Average ~ $0.0035/bhp-hr Downtime over

15 years 280 hours

Electric motors

Less than $10,000/year or$.0004/bhp-hr

Downtime over 15 years 240 hours


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How Does an Engineer Decide?Factors and Examples

Company

ABCProject


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Factors for Deciding Driver & Compressor

Site information

environmental issues

operating conditions

pressure ratios

volume of gas

variability of operation

Owning and operating costs

initial capital expenditure

fuel/electricity costs maintenance

What power is familiar

like to go with what know

Risk assessment power reliability storm outage?

redundancy of units

mix of driver types


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Example 1Project Specifics

4,500 bhp required

Not in non-attainment area emissions not a major issue

Site rated at sea level and 100 degrees (F) ambient temperature

Average operating pressure ratio of 1.3 and discharge pressure of 1100 psi

centrifugal and reciprocating compressors both options

No horsepower in place

no customer preference

2 miles from electricity power source


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Example 1Compression Options

G3616 (4735 bhp, 6736 Btu/bhp-hr)

Gas Turbine (4700 bhp, 9050 Btu/bhp-hr)

5000 bhp electric motor with reciprocating compressor 5000 bhp electric motor with centrifugal compressor


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Example 1Initial Capital Expenditures

$1521

$1501

$1550

$1521

Total

($/bhp)

$7.61$6,605,000$1,000,000$225,000Electric Motor(5000 bhp w/centrifugal)

$7.51$6,505,000$900,000$225,000Electric Motor(5000 bhp w/

reciprocating)

$7.75$4,000,000*$3,750,000$1,950,000Gas Turbine

$7.20$4,000,000*$3,200,000$1,360,000G3616

Total

($MM)

Other Install

Costs

Package CostDriver CostDriver

* Includes facility and additional piping and controls


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Example 1Electric Motor Installation Breakdown

$6,605,000

$6,505,000

Total

$3,000,000$2,000,000$855,000$750,000$1,000,000

(centrifugalcompressor)

$3,000,000$2,000,000$855,000$750,000$900,000

(reciprocatingcompressor)

Facility,controlsand piping

TransmissionLines($1 mill/mi)

Substation witheverythingincluded

VFD($150/bhp)Package


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Example 1Driver and Compressor Owning andOperating Costs* -15 year outlook (15 years covers one major overhaul)

=$29,820,000$.048/bhp-hr=$690,000$.0012/bhp-hrElectric Motor(5000 bhp)

=$20,642,400$.0366/bhp-hr=$2,250,000$.0038/bhp-hrGas Turbine

(4700 hp)

=$15,284,580$.0269/bhp-hr=$2,471,700$.0044/bhp-hrG3616

(4735)

15 Year FuelCost

Fuel/Electricitybhp-hr

15 YearMaintenance

Cost

MaintenanceLifecycle Cost

Driver

8000 hours/year, $4.00/MMBtu, 6.5 cents/kWhr


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Example 1 Driver and Compressor Owningand Operating total Costs*15 year outlook

$7623

$6519

$5270

Total($/bhp)

$38,115,000

$30,642,000

$24,956,280

Total(in millions)

$29,820,000$690,000$7,605,000ElectricMotor

$20,642,000$2,250,000$7,750,000Gas Turbine

$15,284,580$2,471,700$7,200,000G3616

Fuel/Electricity

MaintenanceInitial CapitalExpenditures

Driver

* 8000 hours/year, $4.00/MMBtu, 6.5 cents/kWhr


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Advantages/DisadvantagesReciprocating EngineAdvantages

Fuel efficiency Operation under variable loads and pressure ratios

Well known technology

Disadvantages Emissions

High maintenance intervals and costs

Complex package Lower compressor efficiency at lower pressure ratios


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Advantages/DisadvantagesTurbineAdvantages

Long maintenance intervals

Low emissions Lower first cost for high horsepower applications due to larger

horsepower blocks

Higher efficiencies at lower pressure ratios 1.2

Disadvantages

Fuel consumption

High maintenance costs

Minimal turndown / load reduction Starting and stopping takes hours off life cycle

Altitude and ambient temperature quickly affect power and heat rate


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Advantages/DisadvantagesElectric Motor

Advantages

Low maintenance costs and intervals No emissions at site

Turndown does not affect motor efficiency much

Can be used with centrifugal or reciprocating compressor

Disadvantages

Dependency on power company (interruptions in service)

If high power source not within 2 - 3 miles, installation cost are high(14.7 KV)

Complex controls required (VFD or variable speed gear box)


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Sources

Packagers

Compressor Systems

Inc.Exterran

Others

Alliance Engineering

Miratech EmissionsSolutions

Shermco Industries

ManufacturersAriel CorporationCaterpillarSolar Turbines

Pipeline Companies

Kinder MorganEl Paso Pipeline

Spectra Energy


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ReferencesAriel CorporationAriel Performance Software

Arielcorp.com

Caterpillar Gas EnginesGas Engine Rating Pro software

catoilandgas.cat.com

CAT, CATERPILLAR, their respective logos, "Caterpillar Yellow," the "Power Edge"

trade dress as well as corporate and product identity used herein, are trademarks of

Caterpillar and may not be used without permission.

caterpillar driver comparisons 03022012

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