OPRA orchestrates more cogen in the Russian pipeline

1 October 2006

Two OPRA gas turbines installed in May 2005 at the remote Tedinskoe oil field operated by Lukoil North, the first installation of its kind, are operating at high fuel efficiency in cogeneration mode. Similar installations are in the pipeline.

The Tedinskoe project was implemented by OPRA’s subsidiary in Russia in co-operation with BPC Energy, who provided turnkey services and local installation support. The oil field is a typical example of the smaller, remote oil fields that require onsite power and heat generation to enable oil and gas production to take place. Given current high oil prices, these applications are becoming increasingly attractive for oil companies world-wide. The OP16 is well suited to provide both power and heat to these sites as part of a compact, reliable and high efficiency package.

The OP16s operate on well head gas and are each providing 1.8 MWe which covers the base load electricity demand onsite. In addition, both turbines are connected to hot water boilers which provide approximately 3 MW each in thermal energy. The hot water supply is used for general facilities onsite as well as heat tracing for oil pipelines. The electric efficiency of the installation is approximately 26% but in cogeneration mode the total efficiency is above 75%.

The OP16 was selected because of its ability to burn specification gas but also for its robustness, reliability and high efficiency. Ambient temperatures at the site can be as low as -40ºC with frequent snow storms and high wind loads. OPRA has developed a specially adapted ’Nordic’ package to cope with these adverse weather conditions. The generator packages also need to be light and compact as the only means of transportation is by ’winter roads’ and helicopter.

The two OP16s have to date clocked more than 18 000 hours and are operating 24 hours a day, 7 days a week. The well head gas used to fuel the turbines would otherwise be flared, so this arrangement represents a significant saving in C02 emissions.

The site design work related to this turnkey installation was performed by PermNIPIneft Institute, a general designer of oil field equipment. Construction and installation works were carried out by Globastroi Engineering Co. Project realisation, commissioning and start-up was completed by OPRA Gas Turbines in cooperation with its Russian subsidiary and BPC Energy Systems. The power generation group of Lukoil-Sever supervised the complete project.

Further orders

The Tedinskoe installation represents the first turbine based, small scale cogeneration application for a remote oil field. Since May 2005 OPRA Gas Turbines has received several additional orders, and at least 12 more units will be installed during 2006.

One of these projects is a CHP installation based on OP16 turbines for a new ski resort in the Black Sea area. Multiple OP16 units will provide heat and power to buildings in the resort and associated infrastructure including ski lifts. The absence of a local power grid has dictated the use of onsite CHP solutions which also provide the lowest energy costs. Local heat demand will be supplied by waste heat hot water boilers connected to the OPRA turbines. A natural gas pipeline is already in place and will provide the main fuel supply for the turbines. The OP16s will also have dual fuel capability in case of natural gas supply disruptions. The resort is a green field development and multiple OP16s will be installed in ’blocks’ as the resort expands and more energy is required. Commissioning of the first unit will commence in summer 2006.

The OP16 is rated 1.5–2.0 MW and can effectively cover applications with a electric power requirement up to 10 MW. It has been designed as a simple, robust industrial turbine with low maintenance requirements and high efficiency. It is uniquely characterised by its all-radial design with a single stage centrifugal compressor and a single stage radial inflow turbine mounted back-to-back in a cantilevered bearing suspension system. This enables both bearings to be located in the ’cold’ end providing low operating temperatures and long bearing life. The combustion system is of a 4-can configuration with dual fuel and low emissions options. The combustion system also has the capability to operate on a wide range of both gaseous and liquid fuels.

As part of its ongoing expansion programme OPRA is building a new 5000 m2 facility in Stavanger, Norway. It will incorporate production, testing and development of gas turbines as well as packaging of complete generating sets. OPRA selected Stavanger because of the availability of natural gas as well as the high concentration of oil and gas related companies in the region. OPRA’s existing facility in Hengelo has also been expanded and will in the future focus on the packaging of generating sets and service activities.

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