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Caterpillar Driver Comparisons 03022012
Caterpillar Driver Comparisons 03022012
Compression
A comparison between reciprocating
engines, turbines, and electric motors
Presented by
Wayne Longer
Courtesy of
42 pipeline
Courtesy of
Courtesy of
rte
Courtesy of
Courtesy of
Courtesy of
Company
ABC
Project
Risk assessment
driver reliability - storm outage?
redundancy of units crank failure?
mix of driver types
Driver Options
Driver Options
Reciprocating Engines
Major players
Caterpillar
Waukesha
Wrtsil
CAT G16CM34
Waukesha ATGL16V
Driver Options
Turbines
Major players
Solar Mars 90
Solar
Siemens
Elliot
GE10-2
GE
Rolls-Royce
MAN Turbo
Typical power 1500 - 30,000 bhp
Operate at 11,000 - 23,000 rpm
GE10-1
Driver Options
Electric Motors
Major players
Toshiba
Siemens
Rockwell (formerly Reliance)
Ideal
GE
ABB
Typical power 1300 - 20,000 bhp
Operate typically at 300 - 3600 rpm
Siemens
H-Compact
Siemens
H-Compact PLUS
Compressor Options
Compressor Options
Reciprocating
Major players
Ariel
Dresser-Rand
Cameron Compression
GE
Ariel JGV/6
Dresser-Rand HOS
Cameron Axis
Compressor Options
Centrifugal
Solar C16
Dresser-Rand
Datum
Major players
Solar
Dresser-Rand
Siemens
Rolls Royce
Operates with higher speed drivers (motors
and turbines)
Sweet spot at low pressure ratios and high
volumes
< 1.4 pressure ratio is ideal
Siemens STC-SV
Package Combinations
Package Combinations
Reciprocating Compressor
Recip Engine
Electric Motor
Package Combinations
Centrifugal Compressor
Turbine
Electric Motor
Emerging Technology
Dual Drive
Engine or Electric motor driver
Flexibility lowest cost by the hour
Reduced emissions
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; demand
charges not included and could substantially increase yearly energy cost
Engine
Motors
4700
15,000
27.9%
9125
$1,372,400
(.0366)
501 KC-5
5500
13,600
29.6%
8495
$1,495,120
(.0339)
DDS Frame 8
5360
7000
97.5%
4101
Toshiba/
Siemens
5500
1800
96.5%
4252
$2,132,565
(.0497)
$2,211,040
(.0502)
Btu/bhp-hr
Efficiency
or kW
bhp
rpm
Engines G16CM34
8180
750
42.7%
5959
Wrtsil
16V34SG
Turbines Gas Turbine
9360
750
44.3%
5793
7700
15,000
32%
7960
Gas Turbine
10,310
15,200
34%
7484
Toshiba/
Siemens
10,000
1800
96.5%
7730kwk
Motor
$/year
($/hp-hr)
$1,559,827
(.0238)
$1,735,119
(.0232)
$1,961,344
(.0318)
$2,469,121
(.02993)
$4,019,896
(.0502)
Ratings based on companies published ISO conditions @ 70F Turbines de-rate as temp increases
Demand charges not included and could substantially increase yearly electric costs.
Combined cycle
Electric
Motor Power
5000 bhp =
3731 kW
Demand
Charge
($/kW-Mo)
$6.50
Yearly
Demand
Charge
$291,000
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
Horsepower De-rate
Ambient Temperature
Altitude
Fuel gas
Turbine60
G16CM34 and Taurus
Available Power
9000
8500
Power, bhp
8000
7500
G16CM34
G16CM34
Turbine - 60
Sea(ISO)
level
Taurus
Taurus
Turbine - 60
500(500
ft
ft)
7000
Taurus
ft)
Turbine - 60
1500(1500
ft
6500
6000
5500
0
10
20
30
40
50
60
Temp, degF
70
80
90
100
20
30
40
50
60
70
Centaur
Turbine 50
80
90
100
Emissions
(g/bhp-hr) w/o after treatment
NOx
CO
THC
G3600
0.5 - 0.7
2.5
6.0
GCM34
0.5 0.7
2.0
6.0 - 7.0
0.9
2.0
6.0
0.2 - 0.6
0.6
0.2
Wrtsil
16V34SG
Turbine
Electric Motor
At site only from packaging leaks (valves, vents)
Transfers emissions to power plant
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
Packaging and
Installation Comparison
Package approx
length:
29 feet
116
223
Package approx
width:
Package approx height: 137 inches
178 inches
Note: does not include auxiliary modules, additional piping
Packaging and
Installation - GCM34
Recip compressor
Scrubbers
Pulsation bottles
Gas cooler
Packaging and
Installation - G16CM34
Package approx weight:
300,000 lbs
G16CM34: 179,080 lbs
Compressor: 120,000 lbs
319
185
COOLING SYSTEM
(off skid)
Air ducting
Cooling System
Package controls/electronics
Couplings
Gear box or transmission
Centrifugal compressor
Company
ABC
Project
Risk assessment
power reliability storm outage?
redundancy of units
mix of driver types
Example 1
Project 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
Example 1
Compression 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
Example 1
Initial Capital Expenditures
Driver
Total
($MM)
$7.20
Total
($/bhp)
$1521
G3616
$1,360,000
$3,200,000
Gas Turbine
$1,950,000
$3,750,000
$4,000,000*
$7.75
$1550
Electric Motor
(5000 bhp w/
reciprocating)
Electric Motor
(5000 bhp w/
centrifugal)
$225,000
$900,000
$6,505,000
$7.51
$1501
$225,000
$1,000,000
$6,605,000
$7.61
$1521
Example 1
Electric Motor Installation Breakdown
Package
$900,000
(reciprocating
compressor)
$1,000,000
(centrifugal
compressor)
Total
VFD
Substation with Transmission
($150/bhp)
everything
Lines
included
($1 mill/mi)
Facility,
controls
and piping
$750,000
$855,000
$2,000,000
$3,000,000 $6,505,000
$750,000
$855,000
$2,000,000
$3,000,000 $6,605,000
Example 1
Driver and Compressor Owning and
Operating Costs* 15 year outlook (15 years covers one major overhaul)
Driver
Maintenance
Lifecycle Cost
15 Year
Fuel/Electricity 15 Year Fuel
Maintenance
bhp-hr
Cost
Cost
G3616
(4735)
Gas Turbine
(4700 hp)
Electric Motor
(5000 bhp)
$.0044/bhp-hr
$.0038/bhp-hr
$.0012/bhp-hr
=$690,000
$.048/bhp-hr
=$29,820,000
Initial Capital
Expenditures
Maintenance
Fuel/
Electricity
Total
(in millions)
Total
($/bhp)
G3616
$7,200,000
$2,471,700
$15,284,580
$24,956,280
$5270
Gas Turbine
$7,750,000
$2,250,000
$20,642,000
$30,642,000
$6519
Electric
Motor
$7,605,000
$690,000
$29,820,000
$38,115,000
$7623
Advantages/Disadvantages
Reciprocating Engine
Advantages
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
Advantages/Disadvantages
Turbine
Advantages
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
Advantages/Disadvantages
Electric 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)
Sources
Manufacturers
Ariel Corporation
Caterpillar
Solar Turbines
Pipeline Companies
Kinder Morgan
El Paso Pipeline
Spectra Energy
Others
Alliance Engineering
Miratech Emissions
Solutions
Shermco Industries
Packagers
Compressor Systems
Inc.
Exterran
References
Ariel Corporation
Ariel Performance Software
Arielcorp.com
Caterpillar Gas Engines
Gas Engine Rating Pro software
catoilandgas.cat.com
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