closed cycle vapor turbogenerators (ccvt) for reliable · pdf file ·...

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Copyright © 2015 Ormat Technologies, Inc.

Closed Cycle Vapor Turbogenerators

(CCVT) for Reliable Remote Applications

Jean Gropper

Ormat Power, Inc.

e-mail: [email protected]

Remote Monitoring and Control Conference – Las Vegas

November 5, 2015

mailto:[email protected]


Disclaimer

Information provided during this presentation may contain statements relating to current expectations, estimates, forecasts andprojections about future events that are forward-looking statements as defined in the Private Securities Litigation Reform Act of 1995.

These forward-looking statements generally relate to the company’s plans, objectives and expectations for future operations, and arebased on management’s current estimates and projections of future results or trends. Actual future results may differ materially fromthose projected as a result of certain risks and uncertainties.

For a discussion of such risks and uncertainties, please see risk factors as described in the Annual Report on Form 10-K filed with thesecurities and exchange commission on February 26, 2015.

In addition, during this presentation, statements may be made that include a financial measure defined as non-GAAP financial measuresby the Securities and Exchange Commission, such as EBITDA and adjusted EBITDA. These measures may be different from non-GAAPfinancial measures used by other companies. The presentation of this financial information is not intended to be considered in isolationor as a substitute for the financial information prepared and presented in accordance with GAAP.

Management of Ormat Technologies believes that EBITDA and adjusted EBITDA may provide meaningful supplemental informationregarding liquidity measurement that both management and investors benefit from referring to this non-GAAP financial measures inassessing Ormat Technologies’ liquidity, and when planning and forecasting future periods. This non-GAAP financial measures mayalso facilitate management’s internal comparison to the company’s historical liquidity.

EBITDA and Adjusted EBITDA are not a measurement of financial performance or liquidity under accounting principles generallyaccepted in the United States of America and should not be considered as an alternative to cash flow from operating activities or as ameasure of liquidity or an alternative to net earnings as indicators of our operating performance or any other measures of performancederived in accordance with accounting principles generally accepted in the United States of America. EBITDA and Adjusted EBITDA arepresented because we believe they are frequently used by securities analysts, investors and other interested parties in the evaluation ofa company’s ability to service and/or incur debt. However, other companies in our industry may calculate EBITDA and Adjusted EBITDAdifferently than we do.

Copyright © 2015 Ormat Technologies, Inc. All Rights Reserved. This document contains information proprietary to Ormat Technologies,Inc. Reproduction in any form without prior written permission is strictly prohibited

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Introduction

• The objectives for high reliability in telecommunications, cathodic

protection and SCADA systems in strategic projects are very demanding

• Power generators must operate continuously 24/7, 365 days per year

with high reliability, low maintenance and long life

• The Ormat CCVT was originally part of a program related to the

harnessing of solar energy started in 1958

• Conversion of solar heat into power needed a heat engine to operate at

low temperatures (below 200°C/392°F)

• There were no suitable prime movers for these low temperatures and

small sizes. The steam turbines or steam engines available were almost

useless with these limitations, and gas and hot air engines were entirely

inapplicable

• Decision: to design a prime mover for the application, based on a

Rankine cycle


Introduction

• A turbine was chosen rather than a reciprocating engine

• Steam was replaced by other working fluids

• Criteria for the selection of optimum working were established

• Fluids were selected and tested for stability

• The turbine has been designed to be as reliable and maintenance-free

as possible

• 300W hermetically sealed fuel fired prototypes were operated in 1964

• The inherent high reliability and low maintenance units opened an

application field for fossil fuel-fired units for on-site power generation in

remote locations

• Over 3000 units ranging from 200W to 4kW have been operating

successfully for the last 5 decades

• Hundreds of millions of operating hours in the field, demonstrating the

technical viability of this concept

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The Closed Cycle Vapor Turbogenerator (CCVT)

• The Closed Cycle Vapor Turbogenerator (CCVT) is a Rankine cycle

hermetically sealed turbogenerator having one smoothly rotating

moving part

• The unit is adaptable to a wide range of heat sources including

natural gas, liquid petroleum gases and others

• CCVT operates for many years 24 hours a day; 365 days a year

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1

2

3

4

Burner heats the motive fluid in the

vapor-generator

Motive fluid changes state into vapor

Vapor rotates the turbo-alternator

wheel, creating AC voltage

Vapor flows into the condenser,

cools down and changes state into

liquid


• The alternator is mounted on the same shaft as the turbine and its output voltage

is a function of the rotational speed of the turbine and the stator field excitation

current.

• The power output depends on the amount of heat furnished by the burner.

• The burner is located outside of the sealed system which, unlike internal

combustion engines, isolates the turbine wheel from the combustion

contaminants.

• The alternator and turbine shaft rotate on hydrostatic-hydrodynamic bearings.

• No metal-to-metal contact and, therefore, no mechanical wear.

• The motive fluid lubricates the hydrodynamic bearings, so no external lubrication

is required.

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• Digital Turbine Control Unit for remote monitoring

• Safety, control circuits and devices for fail-safe operation

• Protection against all operational anomalies and malfunctions

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• The output voltage is regulated by controlling the amount of fuel which flows to

the burner. This is accomplished by a pre-set upper and lower voltage sensing

circuit which monitors the output DC voltage and, in turn, closes or opens a fuel

valve

Figure 2 – Block-Diagram of a CCVT unit


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• Over 50 years of field proven experience

• Major telecommunications projects

• Oil and gas industry along pipelines

• Offshore platforms

• DC power for telecommunications networks, telemetry and SCADA

systems, pipeline cathodic protection systems, motorized valve controls,

navigational aids and remote emergency lighting

• Thousands of units in Antarctica, North America, South America, Siberia

and Far East of Russia, Africa, India and Australia

Field Experience with CCVT


Trans - Alaska Pipeline Project

• 122 CCVTs in operation since

1976

• Deployed in the incredibly harsh

Alaskan winter environment

(with temperatures falling to

-60°C in the winter with snow

loads to 90 psi)

• CCVTs, originally designed

for twenty years of service

are still in operation, exceeding

design objectives by more than

twenty years

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CCVT’s on the Trans - Alaska Pipeline


Installation of New 1200W OEC Units in Existing RGV

Station

• Customer’s Request:

• Upgrade and replace the

telecom/RTU/SCADA equipment in

the RGV stations with equipment

that requires almost double

the power

• To avoid the expense of redesigning

and installation of new infrastructure

the original mechanical and electrical

interface between the CCVTs and

the equipment shelter were to

be kept as original

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Gas Pipelines Projects in Siberia

• Very harsh environment -60°C (-76°F) to

+40°C (+104°F) in the summer.

• Proven MTBF = 80,000 hours

(a number of CCVTs have each reached

MTBF of 245,280 hours)

• The proven, recorded mean time

to critical failure (MTBCF) is no

less than 300,000 hours

• Frequency of CCVTs maintenance

services no more than once a year

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CCVTs in a typical site in Siberia


Power Solutions for Sakhalin II Project

• Very harsh environment -39°C (-38°F) to +37°C

(+97°F) in the summer

• Snow thickness = 4 ft

• Earthquakes up to 9.0 on Richter scale

• 102 unattended sites supplied with EPS

(Energy Power Systems) based on CCVT with

battery back-up

• Frequency of CCVTs maintenance

services no more than once a year

• Each EPS comprises also:

1. Gas Pressure Reducing Skid

2. Cathodic Protection Panels

3. VRLA battery for 24 hr back-up

4. Non-electric heating system

5. Telecom and RTU equipment

6. HVAC

• In operation since 2006

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CCVTs in a typical site in Sakhalin


South America Experience.

• Since 1969 over 500 CCVT’s of 600W to 1200W have been powering 5,800km of the microwave telecommunications networks, many of which are still in operation:

• Rio Gallegos – ComodoroRivadavia

• Azul – Mar del Plata

• Mendoza – Cordoba

• Santa Fe – Resistencia

• Rio Grande - Ushuaia.

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Typical Microwave Repeater Site, Ushuaia,

Argentina, Since 1971


Australian Experience

• After over 25 years of

continuous CCVT operation

along the Dampier to Bunbury (DBP)

natural gas pipeline

DBP (WA) Nominees Pty, Ltd.

decided to upgrade the

remote pipeline stations

• Mechanical and electrical

interchangeability with existing CCVT’s

was required in order to keep

the existing infrastructure of the stations

• Harsh Environment with

temperatures reaching

+48 ºC (+117°F) and strong winds

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CCVT remote Power unit along

the 1800km DBP pipeline


Offshore Experience

• Very reliable power source

for application on unmanned

offshore platforms,

despite the harsh operating

conditions

• Providing power for SCADA,

navigation aids and

telemetry systems as well as

for floating and recharging

secondary batteries

• OECs provide the main power for

many offshore, unmanned platforms,

in the Adriatic Sea, South East of Asia

(Indonesia, Malaysia, Thailand, Vietnam)

and in the North Sea

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OECs on an offshore platform in

the Angsi field, Malaysia


Conclusions

• Field proven high inherent reliability

• Hundreds of millions of operating hours in actual field applications

• Lower life cycle cost than alternative systems

• Low maintenance requirements and simplicity

• The CCVT has proven to be a cost effective, dependable and

highly reliable power source

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THANK YOU

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Jean Gropper

Ormat Power, Inc.


Colin Duncan

Ormat Nevada Inc.


Phone: 775-334-0134

Contacts:



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