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HIGH RELIABILITY AND FLEXIBILITY IN POWER GENERATION –

DRESSER-RAND’S KG2 GAS TURBINE

Drilling & CHP applications

The legendary KG2 gas turbine was first installed in 1972. Since then, close to 1,000 units have been installed in 62 countries worldwide, onshore and offshore, in continuous duty operations in all types of environments. The versatile gas turbine generator sets are used for a variety of base load and emergency power generation applications – from fixed and floating installations offshore, to onshore oil fields, on rooftops, and integrated into buildings for simple cycle and combined heat and power (CHP) duties.

With the acquisition of Kongsberg Dresser Power in 1985, Dresser-Rand became the original equip-ment manufacturer (OEM) of the well-proven and highly reliable KG2 product family. Since 1972, Dresser-Rand Norway Operations has developed and implemented a number of improvements and changes for the KG2 gas turbine. These im-provements have increased its power output and efficiency, as well as help control and lower emis-

sions. The product has proven itself in many instal-lations, clocking more than 25 million operating hours with 99% availability. Some engines have been running more than 245,000 hours of con-tinuous duty and achieved a lifetime of more than 30 years of run time.

KG2 gas turbine generator set at the Trans-Tunisian pipeline station in Korba, Tunisia.

© 2013 Dresser-Rand. All rights reserved.2

Gas turbine generator sets

KG2 GAS TURBINE GENERATOR SETS

Two KG2 gas turbine generator sets installed on the Dutch Unocal Helm platform.

The newly released KG2-3G gas turbine is the third generation of this legendary product. It is based upon the same architecture as its earlier ratings, but is equipped with advanced fuel efficiency and dry-low emission (DLE) combustion technologies to meet today’s evermore demanding emission regulations.

While the turbine is still composed of the same proven engine parts (a compact rotor and a

The KG2-3G gas turbine is designed to meet future efficiency and emissions requirements.

© 2013 Dresser-Rand. All rights reserved. 3


THE LATEST GENERATION OF KG2 GAS TURBINES

We maintained the simplicity of the earlier KG2 models, while adding state-of-the-art turbine ma-terials and combustion technology. This allows KG2 gas turbine users to operate their equipment with minimum maintenance and high availability. Maintenance intervals for the KG2-3G gas turbine are 8,000 hours between inspections and 40,000 hours between major overhauls.

The compressor and turbine sections are mounted back-to-back. The rotor assembly is cantilevered so that both rotor bearings are located in the cold end of the gas turbine. As there are no “hot” bear-ings in the KG2-3G gas turbine, the bearings are effectively designed without life limitation. The speed-reduction gearbox is an integral part of the gas turbine and reduces the output speed of the gas turbine to match the generator, while driving the lubrication system and liquid fuel pumps.

single-stage radial compressor and turbine wheel), Dresser-Rand has refined the design and materi-als. With significant improvements in the air-foil design, the efficiency of the KG2-3G gas turbine has increased by 50% compared to the previous KG2 rating. This represents the highest efficiency available for comparably sized gas turbine genera-tor sets. The KG2-3G turbine’s four DLE combus-tors allow for operation below 24 ppm NOx and CO, without any catalytic exhaust remediation.

KG2 users benefit from the turbine’s capability to accept a wide variety of fuels, ranging from pipe-line quality natural gas to low heating value gas (e.g., well head or synthetic gas fuel with signifi-cant hydrogen content). With the capability of ac-cepting fuel gas with 1.5% H2S as standard (high-er levels are subject to review), the KG2-3G gas turbine offers a reliable source of electrical power from associated gas otherwise flared at the well head.



SFC – specific fuel consumption

Note – for operation below -40°C (-40°F), additional inlet and package heating is required.

EGT – exhaust gas temperature

OUTSTANDING FUEL ACCEPTANCE AND OPERATIONAL BENEFITS

The new KG2-3G gas turbine features highly competitive technical data.

Additional operating benefits include the following:

• Requires a low fuel gas supply pressure of 12 bar for operation (and even lower pressure at start-up)• Allows for major load changes of up to 100% with insignificant change in generator frequency• Able to operate with a heat recovery unit to produce more than 6 tons of steam at 12 bar; operating the installation in CHP mode, overall efficiency may exceed 90%.

KG2-3G gas turbine Technical data Metric Imperial Metric Imperial

ISO (15°C/59°F) shaft output

2,000 kW Emission NOx (15% O2) CO (15% O2)

less than 24 ppm10 ppm

Output shaft speed 1,500/1,800 rpm Fuel gas inlet pressure 12 barg 174 psigFuel type Natural gas Generators 400 V to 13.8 kVFuel rate 14,118 kj/kWh 13,381 btu/kWh Weight, gas turbine/gear 1,800 kg 3,968 lbsExhaust gas temperature

577.3°C 1,071°F Typical package weight 16,000 kg 35,300 lbs

Exhaust mas flow 9.4 kg/sec 20.7 lb/sec Package dimensions (L x W x H) - approx.

13.7 x 4.5 x 6.9 m 40’ x 8.6” x 8’



KG2-3G GAS TURBINE FOR OIL AND GAS EXPLORATION APPLICATIONS

With its compact design and low weight, the KG2-3G gas turbine is ideally suited for both on-shore and offshore drilling applications. KG2 gas turbines have an excellent block load capability, which means they can tolerate considerable load changes without having to go offline. This was ex-amined and proven by Esso’s Odin study in 1984; thereafter, the KG2 gas turbine was chosen for several drilling projects.

The KG2-3G gas turbine has good weight to power ratio, and can operate on wellhead or flare gas which offers significant fuel cost savings to the operator. The turbine’s dual fuel capability with seamless changeover under load ensures con-tinuous operation in the event of gas fuel curtail-ment.

Thanks to its small footprint, a KG2-3G genera-tor set can be easily integrated into an existing rig to cover additional power or heating demand. The package can be shipped without load permit which facilitates transport and handling. Our rug-ged package can also withstand transport along rough oilfield roads.

A view of Esso’s Odin platform, where three KG2 gas turbine generator packages are installed. These gas turbines were selected in part for their excellent block load capability.

Three KG2 gas turbine generator sets are running on dual fuel on the Doyon onshore drilling site in Alaska.

Four KG2 gas turbine generator sets deliver power to a Dubai Petroleum Company platform.



KG2-3G GAS TURBINE FOR COMBINED HEAT AND POWER APPLICATIONS

Cogeneration or combined heat and power (CHP) is another suitable application for the versatile KG2-3G gas turbine. CHP systems facilitate elec-tricity production and provide useful heat at very high efficiency. By locating a power generation system at the heart of a facility or process it is possible to capture the heat (usually a wasted by-product of electricity generation). The KG2 cogen-eration system combines the KG2-3G gas turbine with a pre-engineered steam heat recovery pack-age. The system provides a continuous base load supply of both electricity and steam, while lower-ing energy costs and CO2 emissions. With a wide range of steam pressure configurations, this sys-tem can be matched to almost any process need.

CHP 2000 system output Metric Imperial

Electric output 1,950 kWe 2,615 hpElectric generator frequency 50/60 Hz 50/60 HzCHP output choices:

Steam output at 10 bar (145 psi)

7.5 t/h 16.5 klb/hr

Chilling at 37/30°C (98.6/86°F)

5.5 MW 7,375 hp

Hot water from 10-80°C (50-176°F)

16kg/sec 35 lbs/sec

CHP 2000 package data

LTHW flow temperature 82.2°C/180°FLTHW return temperature 71.1°C/160°FNoise dB(A) at 25’ <75GPM of hot water (20°F delta T) 520

CHP 2000 dimension data Metric Imperial

Length 12.192 m 40 ftHeight 2.438 m 8 ftHeight 2.591 m 8 ft 6 inWeight 17.2 t 38,000 lbs

Packaged CHP systems deliver the maximum pos-sible energy cost savings when deployed in appli-cations where the electrical and thermal outputs of the system can be consumed at all times by the host facility. The standard CHP 2000 system delivers high-quality steam for heating purposes. Alternatively, the exhaust energy can be used for chilling and delivers approximately 5.5 MW of chilling power. A balance of both is also possible, as well as the possibility of extracting hot water from the lubricant oil cooler.

Adding a steam condenser can boost the total ef-ficiency of the gas turbine to the mid-90% range. Dresser-Rand CHP systems can be designed to meet a wide range of application-specific require-ments.

Energy consumers demand high efficiency and re-liability in order to minimize operating costs and maximize uptime. KG2-3G CHP systems are sup-plied as comprehensive, factory-tested packages that can be easily integrated into existing site op-erations. Items such as synchronizing switchgear, heat recovery equipment, emissions treatment, attenuation, and lube oil systems are included “within the box.” This dramatically reduces the risk of cost overruns and performance issues as-sociated with traditional “site-built” systems.

The KG2 gas turbines at the McKittrick enhanced oil recov-ery site in California, USA, generate steam that is injected into the oil well to facilitate the oil flow.



Dresser-Rand’s long standing experience with installations for a large variety of applications, combined with the KG2-3G gas turbine’s compet-itive technical features, make these gas turbine packages an ideal solution for the oil and gas and energy markets.

Dresser-Rand’s KG2-3G gas turbine …

• offers an upgraded version of the well-proven KG2 gas turbine.• operates on gaseous and liquid fuels. • accepts a wide fuel range which includes wellhead gas and sour gas with a significant H2S content.• is an excellent solution for recovering flare gas for energy production.• has a dry low emission combustion system for NOx and CO to 24 ppmv at 15% O2 over a wide operating range.• allows for excellent heat recovery in CHP applications.• can operate at extremely low temperatures (as low as -60°C/-76°F).• is designed to operate for 40,000 hours between major overhauls (and one annual visual inspection).• is designed for easy maintenance at low ambient temperatures.• is small and light-weight, built for non-permit shipping loads.• allows for local and remote monitoring and operation, and is also suitable for installations with limited access.

Dresser-Rand’s KG2-3G gas turbine generator packages are delivered completely factory tested. We offer OEM service for operation and mainte-nance for all our KG2 installations.

KG2-3G GAS TURBINE– A RELIABLE ASSET FOR POWER GENERATION

With its rugged steel base frame design, its compact dimensions and low weight, the KG2 gas turbine generator set allows for easy on-site maintenance, as well as simple transport to other locations.

Three KG2 gas turbine packages installed on Shell Malay-sia’s SSB drilling platform.

Dresser-Rand Norway ASP.O. Box 1010N-3601 KongsbergNorwayTel: (Int’l +47 322-87070Fax: (Int’l +47 322-87080

Dresser-Rand West8 Tower Suite 100010205 Westheimer RdHouston, TX 77042, USATel: (Int’l +1) 713 345 6100Fax: (Int’l +1) 713 345 6110

Dresser-Rand112, Avenue KleberCedex 16Paris 75784, FranceTel: (Int’l +33) 156 26 71 71Fax: (Int’l +33) 156 26 71 72

www.dresser-rand.com

This document comprises a general overview of the products described herein. It is solely for informational purposes, does not represent a warranty or guarantee of the information contained herein, and is not to be construed as an offer to sell or a solicita-tion to buy. Contact Dresser-Rand for detailed design and engineering information suitable to your specific applications. Dresser-Rand reserves the right to modify its products and related product information at any time without prior notice.

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