Turbine

Replacement by
electric drive train
Discover a solution that electrifies
your business with rapid success

Abstract
Stricter emission regulations, higher process availability, improved fuel
utilization and reduction of OPEX are some of the reasons to think about
alternative ways to modernize old/conventional turbine trains. All these benefits
could be realized by electric drive systems. Replacing a steam or gas turbine
with an electric drive requires clarification and pre-engineering in order to
analyze the existing drive train, electric grid, foundation, processing machine
and process control system and to confirm the technical feasibility and savings,
respectively the ROI. This white paper describes in general, the requirements
needed to be considered as part of an “overall” solution in order to properly
define the final technical concept and capture the technical as well as overall
economic advantages.

siemens.com/turbine-replacement

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 White paper | Turbine replacement by electric drive train | 7 December 2017

Introduction

Steam or gas turbines in general are used to drive different The optimum power turbine speed depends on the volume
processing machines. Specifically for the Oil & Gas industry, flow input at the power turbine inlet. Increasing inlet air
they are used to drive centrifugal compressors for example temperature means the efficiency, respectively the output
pipeline compression, refrigeration, and gas lift within a power is decreasing.
power range starting from kW up to around 90 MW for LNG
processes. The figure below displays the equipment scope C. Steam turbines
at a summary level. Depending on the converter technology
and the grid optional, a harmonic filter might be required. Next to gas turbines, steam turbines are common. Such
The pure numbers of installed equipment of an e-drive turbines are operating in the so called Claus-Rankine
system is higher compared to a turbine driven solution. Process. Many industrial sites usually have a steam network
Nevertheless an electric solution offers a high number of or steam is generated as a byproduct of a process on site. In
benefits which are explained in this white paper. these instances steam is favorably used to operate the
compressor. In this case replacing it with an electric drive is
A. Centrifugal compressor typically not viable.

Compressors are used to increase the pressure, respectively However there are exceptions that should be taken into
the isentropic heat of a specific medium. Depending on the consideration, for example the steam network, respectively
requirements a compressor is operated within a defined steam balancing requires reduction of the demand, or
area, which can be realized by different methods, like inlet efficiency increase on site leads to less available steam.
or diffusor vanes, throttling (suction, discharge), recycling Under these circumstances, an e-drive should be considered
or variable speed. The last one is the most efficient and as a viable option.
effective, as the driver provides only as much power as
required. Therefore the drive unit must be controllable D. Electric drive train
within the defined speed range of the compressor.
An electric drive train consists of transformer, converter, so
B. Gas turbines called Variable Speed Drive (VSD), electric motor and
optional harmonic filter. Two different types of VSDs can be
Gas fired turbines are split into aero-derivative and heavy used: VSI or LCI. Using load commutating inverter (LCI)
duty. Both are common within Oil & Gas and have different means normally a harmonic filter is required, based on the
advantages and disadvantages. The structure of both of results of a grid study. Also for high power applications
these gas turbine types can be separated into three major around above 25 MW such solution is required. Otherwise
parts: air compression, combustion chamber and turbine. A voltage source inverter technology (VSI) is applicable.
two shaft turbine splits the turbine into compressor and Following two motor types are used: Asynchronous also
power part, compared to the single shaft version. Here the called induction motor and synchronous motor.
compressor turbine is driving the internal air compressor,
and the power turbine on a second shaft provides the
torque and speed on the output site.

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 White paper | Turbine replacement by electric drive train | 7 December 2017

Comparison and potential benefits

For this drive technology comparison example figures are

used which are representative of common value. Depending
for instance on design, ambient conditions, and application,
the parameters will vary. Therefore this paper only presents
indications, not absolute values.

A. Emissions

Combustion of gas is a major source of nitrous oxides,

(NOx), Carbon dioxide (CO 2 ) and carbon monoxide (CO).
CO 2 is regarded as a greenhouse gas with global warming
consequences, while NOx is a regional pollutant causing
acid rain and health complaints. Both emissions are under
stricter regulations whereas the polluters often have to pay
for the emission volumes in form of permits or carbon
offsets. Additionally, more and more governments are
either already taxing or considering taxing large carbon
generators. Following example focuses on the carbon
dioxide. A simple cycle gas turbine produces around C. Efficiency
0,5 kgCO 2 /kWh. To compare this figure of carbon dioxide
emission per kWh output, an ideal gas combustion, The efficiency of a gas turbine depends on the type (aero-
depending on the gas composition, has a value of around derivative or heavy duty), the design parameters and
180 - 200 gCO 2 /kWh. Using as example an 8 MW ambient conditions. Changing ambient conditions also
compressor gas turbine drive train, operating 8.000 hours leads to deviating operation parameters and changing
per year would lead to an annual emission of 32.000 tones efficiencies. The efficiency of an electric motor is specified
CO 2 . It is important to consider that emission control for ambient conditions between -20 and 40 °C (or higher).
technologies, like lower flame temperatures or wet controls By design, the efficiency of such motor is nearly constant
achieve reduction of emission but do so at the cost of lower over a wide ambient temperature range. Exceptionally high
efficiencies. By comparison, operating an electric powered ambient temperatures require a correction factor for
drive train generates no emission on site. Next to downsizing the motor during the design phase.
renewable energy, by moving the combustion cycle for
power generation, there is the additional benefit of moving For the purpose of illustration, assuming a compressor
the carbon generation cycle to a combined cycle turbine efficiency of 83 % and an efficiency of 40 % for an aero-
facility. This facility will operate under maximum efficiency / derivative, the gas turbine drive train has a total efficiency
minimum emission with possible additional scrubbing and of 33 % for ideal conditions (heavy duty around 27 %). The
exhaust gas conditioning. electric drive train, starting from the transformer (99 %),
VSD (99 %), electric motor (98 %) and same compressor
B. Dimension and weight efficiency of 83 % ends up at a total efficiency of 80 %.
Considering a harmonic filter an efficiency value of 99,9 %
Both drive technologies vary within dimensions and weight can be assumed and by this neglected. Even if it is not
depending on manufacturer, type (aero-derivative and relevant for the plant efficiency, including power generation
heavy duty, respectively induction and synchronous), (combined cycle with up to 65 % efficiency), transmission
application, explosion protection, cooling type and so on. It and distribution (95 %), the total efficiency starting from
should be noted that for the electric drive a VSD, power generation is around 50 % for the e-drive train, and
transformer and AMB a control cubicle may be required, but hence still higher compared to a single cycle direct gas
this equipment can be installed within a distance of up to turbine driven compressor.
3.000 m cable length (even higher distances possible). Due
to this fact the VSD is flexible for site planning and could be ɳ𝑔𝑔𝑔𝑔𝑔𝑔 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 (𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎−𝑑𝑑) ∗ ɳ𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 = ɳ𝑔𝑔𝑔𝑔𝑔𝑔 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡−𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
installed in an existing housing or in a container solution 0,40 ∗ 0,83 = 0,33
with separate foundation. The footprint of the electric drive ɳ𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 ∗ ɳ𝑉𝑉𝑉𝑉𝑉𝑉 ∗ ɳ𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 ∗ ɳ𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 = ɳ𝑒𝑒−𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
solution in general requires less space next to the 0,99 ∗ 0,99 ∗ 0,98 ∗ 0,83 = 0,80
compressor compared to the turbine. Of course this has to ɳ𝑔𝑔𝑔𝑔𝑔𝑔 ∗ ɳ𝑑𝑑𝑑𝑑𝑑𝑑 ∗ ɳ𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 ∗ ɳ𝑉𝑉𝑉𝑉𝑉𝑉 ∗ ɳ𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 ∗ ɳ𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 = ɳ𝑒𝑒−𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
be verified for each specific drive/foundation. 0,65 ∗ 0,95 ∗ 0,99 ∗ 0,99 ∗ 0,98 ∗ 0,83 = 0,50

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D. Operating points
Gas Electric
Twin shaft turbines in general have a limited speed range of turbine drive train
0,5 or 0,7 up to 1,05 of the rated power, with a high impact full part full part
on the efficiency and slow speed control response. E-drives Unit
load load load load
can be operated within a wide speed range, starting from operating
0,25 up to 1,2 of the rated power, with a fast response for hours
h/year 8.000 8.000 8.000 8.000
speed control and small variation in efficiency. Also as output
shown in the diagram below, electric high speed motors are power
kW 8.000 6.000 8.000 6.000
able to cover typical gas turbines operating points regarding
ambient efficiency % 35% 28% 95% 94%
the speed and required power. Therefore the operating
temp.
points of the different models of one gas turbine brand are energy
15°C GWh ∼ 180 ∼ 170 ∼ 65 ∼ 50
used (white points in the diagram). The replacement can demand
(ISO)
take place without any translation of speed and torque. The
electric high speed motor curve represents the maximum ambient efficiency % 21% 18% 95% 94%

speed for the specific output power, thus operating points temp.
energy
40°C GWh ∼ 300 ∼ 270 ∼ 65 ∼ 50
below this line can be covered by direct electric motor drive. demand
Table: Energy demand (different load, ambient temp.)

E. Start-up & stop process

Aero-derivative gas turbines are able to start within around

10 min, without impact on life cycle. For heavy duty types
the start from idle speed is around 10 to 15 min. Starting
from operation at full load until stop roughly the same time
as for the start could be assumed. Depending on the mass
the heavy duty turbine maintenance shut down take even
longer, up to a few hours, because of the cooling process.
Furthermore if there is no restart within a defined time, a
full machine cool down must take place.

Assuming again an 8 MW electric high speed motor with

14.000 rpm and a moment of inertia of 20 kgm2, directly
Based on the wider and more efficient speed range of an operating a centrifugal compressor (Neglecting the
electric drive solution, the following application example limitations for the compressor start process and focusing
describes how these advantages can be used. The suction only on the e-drive), the start-up time is less than
pressure in depleting gas fields declines over years. This 4 minutes. After the start signal the VSD limits the current,
requires continuously increasing compressor power. In a depending on the motor nominal current value and runs up
conventional compression design, a completely new to the operating point (here 7,6 MW, 13.500 rpm).
additional compressor string is required when the Assessing the stop process an electric motor for compressor
production cannot be maintained with only one applications usually does not require active braking,
compressor. To minimize the capital expenditure, short concerning the motor or VSD. After the stop signal the
CAPEX, a double shaft end motor can be used, allowing motor coasts until standstill. The number of start & stops
upgrade from one to two compressors. This enables a just- processes within a short time is almost only limited by the
in-time high efficient adaptation of the compressor power cooling capacity of the VSD and motor. Usually repeated
without requiring a second driver. starting within a short time is no problem from the driver’s
point of view.
To explain the theory of ambient and load impact, following
Table is used. An 8 MW drive with full load and three- As a result the e-drive train provides a simple and fast start
fourths load is operating 8.000 hours per year once at ISO and stop process. This behavior affects also the downtime
conditions and once at 40°C. Based on assumptions for the regarding maintenance.
efficiency the energy demand is shown. The gas turbine
requires at full load and ISO conditions around 180 GWh, F. Maintenance
and 300 GWh for the higher ambient temperature. It can be
seen that for the electric drive train the efficiency and Neglecting the auxiliary equipment, like purging and
hence the energy demand does not change regarding these lubrication systems. For the turbine maintenance schedule
ambient temperatures. The energy demand of an e-drive for so called equivalent operating hours, short EOH, are usually
this example is at least 30 % compared to the turbine taken into account. This value is calculated via the data of
demand. This energy savings increase further for part load operating hours per year, the stress factor (type of load),
and higher temperatures. the number and type (normal, fast) of start / stop. A higher

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 White paper | Turbine replacement by electric drive train | 7 December 2017

EOH means higher maintenance effort. Further factors like

fuel quality, age of the turbine and performance parameters
have to be considered also. It is important to separate aero-
derivative and heavy duty. Based on these parameters and
the visual inspection, the required maintenance and
overhaul of turbines is defined. The service can be
separated into three major categories:

- Minor overhaul: remote online check, change of the

filters, bore scope inspection of compressor casing,
vanes and blades, burners, combustion chamber,
turbine vanes and blades. Inspection of: auxiliaries,
driven equipment, main gear and coupling.
Each year; G. Reliability / Availability & Stand by
on site;

- Hot path inspection: everything out of the minor For reliability, availability or mean time between failures
overhaul, including the inspection of the hot path. (MTBF) different definitions respectively calculations are
Depending on operation parameters; common and hence hard to compare. Reliability itself is
on site; defined as the probability that an item can perform a
required function under given conditions for a given time
- Major overhaul: everything out of hot path interval (IEC 60050-191). Availability can be described as
inspection, the turbine is general overhauled.
possible operating time considering all scheduled and
Depending on operation parameters (every 6…9
unscheduled downtimes, like service or failure.
years);
Not on site;
The reliability of turbines increased during the last decades,
especially because of the aero-derivative type. However the
It can be assumed that for an aero-derivative within the first
installed base of turbines within the Oil&Gas industry is
100.000 operating hours 40 days and for the heavy duty
aging, which lead to decreasing efficiency and reliability
between 100 and 140 days are required. That means
values for the installed fleet. Using turbines means
average around 3 days, respectively 8 days per annum.
operating many rotating parts, high temperatures and high
stresses for components, which leads to a low value of
Assessing the maintenance of e-drive with magnetic
reliability (compared to e-drive). Gas turbines have often
bearings, a yearly visual inspection, performed during
identical core engines with commonality of spare parts,
operation, is recommended. Such driver is independent of
which allows spare part management over a regional pool.
an operating hour (EOH) calculation for the maintenance
Short spare part delivery time, and reduced spare parts
plan. Thanks to their non-contacting design, magnetic
costs are feasible. However, due to the amount of
bearings are practically maintenance-free. Furthermore no
components, it is still required to have more spare parts
oil system has to be checked and maintained. Roughly every
compared to the e-drive.
four years a more detailed motor inspection should take
place, including for instance borescope inspection and
If a critical process has to be driven, considering the storage
isolation resistance checks of rotor and stator and the
of the critical parts, like spare rotor or even a spare motor
cooling system, which service, depending on the motor, can
on site, increases the availability with a small invest
take up to 3 days. For the VSD it is recommended to
compared to losses because of unplanned downtime. Such
consider one day for service each year. Additionally visual
solution should be compared to the spare part management
inspection of the fans, water connection, if water cooled
effort for gas turbines individually.
and functions test like for the power bank should be
performed. Under favorable ambient and operating
Considering the availability it is possible to operate the
conditions the maintenance intervals can be significantly
e-drive years without downtime. Such a drive is a
extended after the first year.
sophisticated technology with less rotating parts. Even so it
is designed for high availability, specific VSDs are using
An e-drive train needs no general overhaul within around
bypass power cells, which bypasses faulty cells
20 - 25 years, depending on ambient and operating
automatically without shutdown. During shutdown it can be
conditions. Inspection and service during this time period
changed within minutes, due to the design as closed
can be performed on-site and within a few days only, which
component to plug in.
results in a low maintenance drive technology, compared to
a turbine. Furthermore, due to drive train analysis and
Compressors and gas turbines can fail during a starting
visual inspection during operation it is possible to operate
process, for example if the required speed is not reached
for up to 4 or even 5 years without shutdown. Less
within a defined time. Such situation leads to starting
downtime, less effort, leads to less cost and higher
process breakup, cooling time and re-start. Using an e-drive,
availability.

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 White paper | Turbine replacement by electric drive train | 7 December 2017

out of an electrical point of view, the starting process is systems require a more detailed consideration because of
uncritical. the alternate up and down time.
Without going into detailed description of the methods,
assumptions and failures, gas turbines have a common
reliability value of around 97 - 98 % (availably of around 95
- 96 %), compared to possible values of 99,9 % for reliability
and availability for electric drive trains. For a reliable
statement regarding availability of the electric drive train
the electric power supply has to be considered, which leads
to a very specific calculation and comparison of each
individual site.

H. Total costs of ownership

For a comprehensive economic assessment of turbine and

e-drive the total cost of ownership are compared, thus the
CAPEX and OPEX for the planned life time. It should be
distinguished between two different investment
calculations - green field (new installation) or brownfield
CO 2 emission is a local parameter. For the respective
(replacement of old existing turbine). For a green field
regions the emission of the turbine has to be taken into
installation the CAPEX between a new turbine and a new e-
account and multiplied with the tax per ton CO 2 or
drive train has to be considered in addition to the operation
respectively payment for the emission. Parameters differ
costs. The investment in a new drive at a brownfield case
from region to region.
has to depreciate itself via the savings. Here the key
criterion is the return on investment (ROI).
Insurance costs for a gas turbine can be high due to fire
hazard, compared to the possibility for a pressure resistant
The CAPEX for the drives are depending on many factors. As
casing and non-sparking electric motor design. Also the
a consequence it is not possible to bring it down to one
flexibility to install the VSD within 3000 m cable lengths,
value, like comparing the invest per output power [€/kW].
means installation in non-hazard is possible. This parameter
Regarding the OPEX, following topics have to be analysed
has to be checked and possibly deviations for the insurance
for turbine and e-drive separately:
fee calculated.
Next to the energy source price, gas and electricity, the
The amount for the investment has to be evaluated, starting
operating points are important. Comparing the full load
for the first analyses with estimations and budget values
efficiency does not represent the operating conditions
after detailed technical studies.
during life time. Such study of an existing site brings the
benefit of utilizing the real operating data from the past, in
specific the different loads over time and ambient
conditions of the last year. On the basis of this site data the
specific efficiencies for the different load, the required
power, the operating time and the energy costs can be
calculated. Another parameter for some applications (like
gas pipeline compressor station) is to use electricity means
to sell the not burned gas, hence potential to increase the
turnover.

As mentioned already, the turbine and e-drive maintenance

verifies. Considering this difference it is worth to have a
closer look. A comprehensive approach will be to compare
long term service agreements, short LTSA, for both
technologies. Such agreements will include the
maintenance schedule, effort, required man power and
spare parts. Such comparison indicates that the e-drive has
an easier maintenance concept and brings financial benefits
due to the explained technical advantages.

Depending on the required uptime, based on the reliability

and availability of both drives, values for planned and
unplanned downtime should be considered also. Redundant

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Scope of work

The Analysis, Pre-FEED or FEED to replace an existing gas cable planning, combine consumption list of reused and
turbine in a brown field needs an actual recording of current new equipment/consumers and so on.
drive train and site data. Talking about green field the same
working packages have to be gone through, and checked if D. Electric drive train
relevant or not. The following picture shows the major
topics have to be analyzed. On the basis of operating data from the past or considering
prospective growing demand, an electric drive train is
A. Processing machine / Pre conditions engineered according to the parameters (speed, torque,
footprint, etc.). If space is available within a building an
Reuse of the compressor requires a data acquisition for existing room can be used for the VSD cabinets (bring in
designing the suiting new drive and furthermore to create concept has to be considered), otherwise an e-house can be
out of the whole drive the model for torsional and string installed on site.
calculations. The same data acquisition applies for the
existing foundation, the drawings have to be checked and E. Process Control System
whether any changes during life time were executed. Also
site drawings should be analysed concerning the available For the new concept of the drive train, the concept of the
space for additional new equipment like transformer or existing process control system must be adapted and
e-house, and also e.g. crane for the revamp work. configured. This requires expert knowledge on the existing
system on site and the control systematic of the VSD which
B. Infrastructure has to be attached and configured to the overall control
unit. A detailed engineering process on this working
It has to be considered whether the existing equipment like package has to define the interphase between new and
re-cooling unit or lubrication system can be reused, and existing system.
which possible changes are required. Also it is possible to
consider the installation of an e-house, which leads, due to F. Project Management
a pre-mounted and tested equipment (VSD, switchboard,
MMC, etc.) to less effort and risk on site. Next to the Summarizing the required data, organizing a site survey,
transformer housings, the cable tracing and e-house capturing the information such as available space,
foundation could be prepared / executed in advance during compressor details, electric grid and existing process control
operation. Such options have to be considered within the unit with focus on the interface, are representing the first
basic design phase. steps of the project manager within such study phase. After
execution of all further descripted working packages, like
C. Engineering & Studies drive train design and foundation analysis the site activities
have to be worked out in a preliminary form to plan
Before considering the drive train itself the availability and dismantling, installation, commissioning, required tools,
capacity of the electric energy source has to be inspected. man power, time schedule and last but not least the costs.
Therefore based on the required load and the data of the Furthermore for a long term OPEX comparison, a service
existing grid, a grid study including network concept, concept for the new installed equipment needs to be
harmonics, power factor corrector, protection philosophy, defined, which includes for example the spare part concept
safety concept, grounding and optional filter design and service intervals.
(depending on the used drive) should be performed. If
required also the connection of the site to the electric grid G. Replacement budget and ROI calculation
could be considered.
The investment consists, next to the equipment costs, of
Analyze the new system (motor, compressor) regarding the civil work, turbine dismantling, installation and so on,
foundation and string should also be part of such pre- should cover all costs starting from the FEED until the new
engineering. Starting from measuring the existing e-drive runs up (after acceptance test). The OPEX of the
foundation and data capturing of the compressor, creating existing turbine has to be compared with the designed e-
calculation models, a foundation, string and vibration drive train OPEX over the life time including case studies for
analysis can be performed. Within this stage possible gas and electricity price trends.
countermeasures could be defined and implemented for the
motor design to keep the adjustments on site as small as
possible. Further working packages within this stage are

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 White paper | Turbine replacement by electric drive train | 7 December 2017

Conclusion
“The electric light did not come from the continuous
improvement of candles” (quote from Oren Harari), in
other words the electric drive train offers the flexibility
to meet changing demands, lowers the environmental
impact, offers a higher level of availability and comes
along with higher efficiency. But such change from one
drive technology to another requires a detailed
pre-engineering. Therefore different working packages
of various fields have to be considered to define the
technical feasibility, and elaborate the benefits. To
obtain a reliable study an experienced partner with
equipment and project knowhow should be involved to
consider the entire scope. Nevertheless the potential of
such drive change is extensive and is worth the effort.

Published by
Siemens AG 2017

Process Industries and Drives Division

Gugelstrasse 65
90459 Nuremberg

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