Power for the pipeline: Northern Power Systems supplying Kohler gen-set systems for $12 billion Russian oil & gas project

Diesel Progress North American Edition, Nov, 2005 by Dawn Geske

Waitsfield, Vt.-based Northern Power Systems has entered into a contract to provide on-site power using its TeleCycle and TelePrime power systems for Russia's Sakhalin-1 pipeline project. The approximately $5 million power generation contract with Exxon Mobil Corp.'s subsidiary Exxon Neftegas Limited, which is spearheading the Sakhalin-1 project, will provide power during the development and operation of the estimated $12 billion pipeline project to transport oil & gas across the Sakhalin Island and into the Russian mainland.

The Sakhalin-1 pipeline project involves the construction of both off-shore and shore-based facilities, including what is expected to be the world's largest land-based drilling rig, which will use extended-reach drilling to reach reserves six miles from shore. In addition, an offshore platform will provide drilling capacity for as many as 20 wells, an onshore oil & gas processing facility will be installed as well as a 140-mile crude oil pipeline and marine export terminal.

When completed, the Sakhalin-1 project is expected to produce and transport 250,000 barrels a day of crude oil by the end of 2006 and an estimated 60 million cu.ft. per day of natural gas, increasing to 250 million cu.ft. by the end of 2010. All natural gas production will initially be sold to Russian power utility OAO Khabarovskenergo and gas retailer OAO Khabarovskkraigas, while the oil produced will be sold into the Russian domestic market and then internationally.

The area being developed is situated along the eastern coastline of Russia, just north of Japan. It is here that the Sakhalin-1 consortium will begin development of the Chayvo oilfield, followed by the Odoptu and Arkutun-Dagi fields in phase two and three of the project. It is in this remote area that Northern's power systems will be put to use, offering cycle-charge and redundant power system architectures to reduce maintenance intervals, engine runtime and fuel usage.

The electricity being provided at this location will be used to power telecommunication, instrumentation, block valve actuation and controls that Exxon uses to provide valve blocking, actuation, metering and cathodic protection to the pipeline.

Shipping its first four units in February, Northern Power recently began installing the 35 kW and 80 kW TeleCycle diesel power systems. The TeleCycle system provides power by running off a battery bank that is periodically recharged by one of two diesel gen-sets. Using this system requires only intermittent use of the generators, minimizing engine runtime and fuel usage, said Northern.

Each TeleCycle system is outfitted with a full shelter, powered by two gen-sets, with remote system monitoring capability and safety and security systems in place. Generators on these units include Kohler's 35 kW and 80 kW (125 kVa) diesel-powered units.

The 35 kW package is equipped with a 4.5 L four-cylinder John Deere 4045 turbocharged diesel engine rated 56 hp. The larger 80 kW system is driven by 6.79 L six-cylinder John Deere 6068 turbocharged engine rated 129 hp.

Electrical power output is produced by a Kohler four-pole, rotating field alternator equipped with its Fast-Response PMG excitation system. It incorporates a brushless, permanent magnet design, is drip-proof, self-ventilated and fitted with a 2/3 pitch stator and skewed rotor.

The TeleCycle system also incorporates a Chloride dc UPS which combines rectifier and inverter functions, delivering the ac power from the alternator to the dc power load and supplying the battery storage bank. GNB batteries are used in the storage bank and a Mitsubishi HVAC system is used to control temperature inside the shelter. Battery capacity is designed for a three-day charge at full load, cycling down to 40% capacity.

At the heart of the TeleCycle power system is Northern Power's PLC-based controller which monitors all system functions including air temperatures, gen-set status, battery state of charge and fuel level. In hot weather, the system controller automatically opens vents, turns on fans or activates air cooling. In colder temperatures, heat from the gen-sets and load consuming equipment is captured to warm the interior of the shelters.

Diesel fuel tanks are located within the shelter with storage capacity up to 4000 gal. An external fuel port, equipped with spill prevention and a level indicator, allows refueling through tanker tracks. The complete TeleCycle system is designed for deployment anywhere in the world using self-contained specially modified ISO shipping containers. Design life on the power systems is 30 years, said Northern.

The Sakhalin-1 project also included adding one of Northern Power's TelePrime systems, a continuous operation system with redundant natural gas gen-sets for greater reliability and extended service intervals. This 82 kW (103 kVa) package is packaged with two Kohler 125RZG gen-sets, powered by an 8.1 L eight-cylinder GM Vortec turbocharged natural gas engine rated 129 hp.

The engine is paired with a Kohler alternator and features similar components as the TeleCycle system such as Chloride UPS, GNB batteries, Mitsubishi HVAC and Northern's system controller. The TelePrime system is fueled via the island's natural gas pipeline.