Products

 

CUSTOMIZED ENERGY SOLUTIONS

Gas Turbine Upto 500 kW

Current Electrical Power Source at Remote Oil Fields

At Remote Oil Fields, the Source of Electric Power for Day to Day Process Operations shall be through two means:

  1. Diesel Engine Generators
  1. From Very Long Distant Power Source Through Composite Cables

Both of these have their own disadvantages.
The Use of Diesel Engine Generators calls for;

  • Frequent Refuelling (Logistics & Dedicated Personnel)
  • Checking (Skilled Personnel)
  • Maintenance (Often Deputation required from OEM)
diesel-engine-uses

Similarly, When Power is transmitted through Long Distant Composite Cables, there is an Add on Power Factor Correction needed. To accomplish this, there needs to be Installation, Monitoring and Maintenance of Capacitor Banks. These again call for Skilled Manpower. Furthermore, a Significant Amount of Electrical Energy is already compromised.

TurboTech Energy Offering of New Electric Power Source

At Remote Oil Fields:

Gas is a Generated By-Product of the Upstream Process (Crude Production from Wells). By Utilizing this Gas as the Fuel, A Gas Turbine Generator shall be Operated and used as a Captive Source of Electric Power. Since the Upstream Process is a continuous 24×7 process, the Gas Availability also becomes 24×7.

TurboTech Energy USA conducted Application Engineering Study and Based on the Technical and Practical Requirements Capture: The Subject Gas Turbine Generator Solution was DESIGNED, DEVELOPED, PILOTED and SUCCESSFULLY IMPLEMENTED at Remote Oil Fields of Customers at Kingdom of Saudi Arabia and South Korea.

Desired Fuel Characteristics

Gas Inlet Pressure:
Min 100mmwc to 1 PSIG, Max at 140 PSIG*
Gas Inlet Temperature:
Min 1 Deg C to Max 75 Deg C
Gas Calorific Value:
Min 325 WI Btu/ft3 to Max 1900 WI Btu/ft3*

*Fuel Gas Boosters shall be provided if required by TurboTech Energy

Salient Features of the Package – Direct Benefits to Customer

The Following Features are incorporated in the Gas Turbine Generator Package to Ensure High Availability, Safety and Reliability Benefits to End Customer.

Electrical

  1. Suitable for Both 50Hz and 60Hz Cycle Operations (Anywhere across the Globe).
  2. Synchronous Generator to Facilitate Island Mode of Operation. Also, If demanded, TurboTech Energy USA has a Special Design Provision to Offer with Asynchronous Generator so that the Power shall be hooked up (synchronized) to the Existing Power Source (Sophisticated Management of Varying/Constant Electrical Loads).

Thermal

  1. Heat Recovery as an Optional Integrated Unit (Maximised Efficiency).
  2. Patented Technology to Ensure Full Compliance to Emission Standards.

Mechanical

  1. Back to Back Rotating Components–Lowest Maintenance Required.
  2. Total Maintenance Time Period Required Per Year – 4 Days ON SITE…
salient-image

Electrical

Installation

  1. Weatherproof Enclosure.
  2. Noise Proof < 80 DBA.
  3. Skid Mounted with the Lowest Foot Print – LxBxH = 4.25 M x 2 M x 4.25 M.
  4. Lightest Weight: <7000 Kgs.

Instrumentation & Controls

Main + Redundant Instrumentation for all Critical Parameters. Total Control through an Integrated System based on PLC. First Alarm, Second Alarm and Moving to Tripping Mode in A Very Practical Sense with Focus on Protection of Equipment, Personnel and Environment.

Pre Start Routine through an Auto Check Mechanism, Post Which OK TO START Signal is given for Start of the Gas Turbine (High Safety Interlocks Incorporated, No Bypass allowed).

Remote Monitoring & Reporting

  1. Ethernet Interface for Remote Monitoring, Operations and Control from Control Room.
  2. Recording Mechanism on all Critical Parameters on Minute by Minute Operations.
  3. Management Information System for Auto Reporting on Trends of Fuel Consumption Vs Power Generated in line with Electrical Load Addition and Removal Pattern.

 

 

ENERGY CONSERVATION STEAM TURBINES UPTO 5.5 MW

One -of-a-Kind Turbo-Driven Solutions

At TurboTech, we have analysed and implemented a unique way of harnessing the potential of steam driven turbo drives whilst commanding superior controllability throughout. We have had a plethora of experience in this field as we have provided the Process Industry and power plants with more than 135 Steam Turbines to date.

This unique way of coupling the turbine generator with a pump is yet another value added initiative to support our customers with reliable, sophisticated, and state-of-the-art turbomachinery.

The Benefits of Our Steam-Driven Turbo Solution

  1. In case of a total black out or sudden loss of electric power at the process plant or the power plant, the Steam-Driven Turbo Drive will ensure minimum pressurised feed water flow to the boiler system and thus ensures utmost safety in cases of extremities. This feature is not available on existing systems in the market and thus through this particular solution, there is safety and reliability is incorporated at triple redundant level.
  2. At all times, the pump is driven with the steam source energy, the customer is directly achieving equivalent electrical unit savings that would otherwise be spent from their plant grid.
  1. Since there is auto control in the system, there is no need for a specially trained operator to be present for running the feed pump, reducing costs, manpower and room for potential error.
  2. There is a dual saving opportunity for the customer both in terms of electrical cost savings through their variable frequency drive systems (VFDS) and also the steam turbine generator system. This is because the controllability being in AUTO Mode for both the induction motor and steam turbine being online at all times facilitates the continued use of VFDS on the plant side.

Overview of our Energy
Conservation Turbines

Our bespoke Energy Conservation Turbines are reliable, efficient and forward-thinking turbine solutions, they can aid your organization in acheiving tight efficiency targets, cut costs and help promote a greener tomorrow. They are easily maintained, user friendly and have a short pay-back period of 6 to 18 months.

 

TURBINES ARE CUSTOM DESIGNED FOR EVERY APPLICATION TO GIVE YOU MAXIMUM, CONTINUOUS POWER, WITH NO TWO TURBINES EVER PRODUCED BEING THE SAME

Practical Applications

Our custom made Turbines are extremely versatile and can be applied in the renewable energy sector, energy co-generation, CHP, WHR and the field of captive power.

Cost savings can be found in the form of a reduction in power costs as Steam Turbines can be installed in parallell with pressure reducing valves or pressure reducing desuperheater stations. Any steam energy wasted due to pressure reduction can be recovered easily in the form of electrical power and can further benefit the generation process.

Key Highlights

  • High speed of the turbine means
    high efficiency in small sizes.
  • Wet steam resistant design.
  • Single lightweight skid.
  • User-friendly digital controls.
  • Payback period of 6 – 18 months.
  • Proven GHG reduction potential, about 120,000 T-CO2, increasing to more than 1,000,000 T- CO2 in 5 years.
  • Island foundation not required, resulting in easy setup.
  • Easy maintenance for long term management.
  • User-friendly digital controls.
  • High utilization factor (about 80 – 95%) which is the most efficient when compared to other clean-tech investments.
 

SATURATED STEAM TURBINES

Energy Capture from Saturated Steam

Our Energy Capture Turbines can be used effectively in capturing energy from saturated steam which has high heat transfer capabilities and can be used in diverse applications.

Using our turbines with Saturated Steam

Despite its many uses, saturated steam can erode and deteriorate conventional turbines due to the presence of water droplets, causing the vanes to break which can cause steam leakage. Also, saturated steam fails to push on the vanes of a turbine, which results in a loss of energy. This renders conventional turbines unusable in capturing energy from saturated steam.

The special design and austenistic stainless steel materials used in all of our Steam Turbines gives us the ability to utilize saturated steam without adhering to the shortfalls faced with regular turbines. Our rotors are crafted from a single block and designed to take up speeds thrice its running speed, proving that our turbines are suited for using saturated steam to its full potential and are extremely robust.

 

Salient Features:

  • High speed turbines, i.e,.high efficiency in small sizes.
  • Wet steam resistant design
  • Single lightweight skid.
  • User-friendly digital controls.
  • Payback period of 6 – 18 months.
  • Proven GHG reduction potential, about 120,000. T-CO2 , increasing to more than 1,000,000 T- CO2 in 5 years.
  • High utilization factor (about 80 – 95%) most efficient when compared to other clean-tech investments.
  • Island foundation not required, easy installation.
  • Maintenance freindly design.

 

TURBO EXPANDERS UPTO 3 MW

Introduction

Standard/Modified Rankine Cycle
There are Two Prime Reasons why we use Water as the EXTENSIVE Energy Carrying Fluid in All Industrial and Utility Processes:

It is Available in Abundance.
It is a Pure Substance (Exhibits Homogeneity when subject to Reversible Thermal Processes) Let us take Two Thermal Processes that is very common in any Thermodynamic Cycle.

Evaporation & Condensation…

If we subject Water to both these processes simultaneously, even then water will still remain intact with its Molecular Structure. This property of water is called as Homogeneity which means not losing its structure due to thermal formation or deformation.

The above is the Fundamental Reason why Watern is used as the Fluid in the WORLD FAMOUS THERMODYNAMIC CYCLE called as RANKINE CYCLE. A Slightly modified version of Rankine Cycle that involves both Regeneration and Reheat is called “Modified RANKINE CYCLE”.

It is important to note that Modified RANKINE CYCLE is the Basis for Operation of More than 40% of the Worlds Power Plants Today to Generate Electricity.

Having said all this:
Interestingly, when it comes to ORGANIC RANKINE CYCLE, Water is not used as the Energy Carrying Fluid.

The Problem with Modified Rankine Cycle is that the Water Evaporates only at 100 Deg C and above, that means there is no provision for using the same Thermodynamic Cycle when it comes to Lower Temperature Heat Sources.

Hence in order to capitalize heat recovery from Low Temperature Heat Resources, Organic Rankine Cycle is practised and utilized.

 

Introduction to Organic Rankine Cycle & ORC Turbine

The Principle of ORC
Organic Rankine Cycle works on the Principle thatEnergy Carrying Fluid should Boil (Evaporate) at Lower Temperatures WELL BELOW 100 Deg C. The following are the series of steps that is performed during an Organic Rankine Cycle to recover waste heat andconvert it to useful electric power.

orc-turbine

Steps Involved in ORC

  1. ORC Fluid – PFP (Refer Section 1.2.4) is pumped through to raise its Pressure as required.
  2. It is passed through a Heat Exchanger (HX) where it get itself evaporated with Heat from Heat Source: Source of Heat for HX: Customers Low Temperature Heat Source.
  3. This Evaporated ORC Fluid is now passed through the ORC Turbine Generator and Electricity is Generated in proportion.
  1. The ORC Vapour is now cooled through a Condensing System. The warmed up water shall be used for Heating Purposes in the near vicinity.
  2. Condensed ORC Fluid is pumped back and theEntire Cycle is Repeated.

ORC Turbine Fluid & Its Properties

There are Several Energy Carrying Fluids that shall be used in Organic Rankine Cycle

The Fluid used by TurboTech Energy on their ORC Turbines is HFC-245FA (PFP) whose properties are defined below:

Energy Carrying Fluid:

HFC, Hydro Fluoro Carbon – HFC-245FA

Molecular Formula:

C3H3F5

Chemical Name:

Penta Flouro Propane (PFP)

Boiling Point

As Low As 15.3 Deg C under Standard Atmospheric Conditions

Nature

Non Toxic, with Auto Ignition Temperature: 412 Deg C

Applications Suitable for Heat Recovery through ORC

Any Industry Application in which Heat is rejected at a Temperature of 200 Deg C and above (Or)
Any Renewable Energy Source in which Heat is generated Up to a Temperature of 100 Deg C

Engineering Support from TurboTech Energy to Customers

Customer shall furnish the details on the following to Team TurboTech Energy for a thorough analysis and feedback on the Potential of Installing an ORC Turbine against their Low Temperature Heat Source:

  1. The Heat Source (Exhaust Gas). Parameters (Volume Flow, Pressure, Temperature, Composition).
  1. Minimum Exhaust Temperature at which the Exhaust Gas. is to be released to atmosphere…