Oil Production Offshore Platform Power Management and Emissions Treatments
GCS was contacted by an offshore operator to install air fuel ratio control systems on six Waukesha generators on an offshore rig. The new system incorporates modern digital speed, air fuel ratio control and exhaust catalysts for improved speed and emissions controls. The original fuel system had Fisher regulators and OEM diaphram carburetors which were prone to drift with load changes. The Gulf of Mexico offshore platform was experiencing such high CO concentrations that emergency rig evacuation events occurred due to the excessive CO levels in the onboard living quarters.
- Power Generation; Emissions Controls
- 6 Waukesha 900 rpm, 600 kW G7042 gas engines
- Woodward easYgen 3100/3200 Genset Control for Multiple Unit Operation
- Woodward E3 Rich Burn Trim
The Woodward E3 Rich-Burn Trim Integrated Gas Engine Control System analyzes and controls the spark, fuel and air functions of the engine and catalyst, optimizing the amount of time the engine is in compliance. The E3 StableSense natural gas O2 sensor is unaffected by engine exhaust methane and hydrogen. Misfire detection, health monitoring, and engine protection are integrated into the E3.
- Woodward L-Series ITB Valve
The L-Series Position Controller is an extremely fast bi-directional actuator that regulates the air-fuel mixture.
- DCL 3-way Catalysts, Exhaust Silencers, and Heat Blankets
DCL three-way catalysts convert nitrogen (NOx), carbon monoxide (CO), hydrocarbons (HC), formaldehyde (CH2O), and EPA classified Hazardous Air Pollutants (HAPs). DCL QUICK-LID catalytic silencer reduces engine exhaust noise and emissions in a single integrated unit.
- HMI Remote Monitoring System
Color touchscreen HMI Operator Panel displays all relevant information available from the E-3, providing the operator with valuable information to monitor and troubleshoot all functions of the entire control system
The structure is three separate platforms which are umbilicalled together. Two of the three platforms have three Waukesha 600 KW generators each which supply power for all three platforms. GCS implemented a control system consisting of a customized Woodward E3 Air Fuel Ratio control with Woodward Stablesense oxygen sensors, DCL three-way catalyst, exhaust silencers, L-Series ITB fuel valves, MAP / MAT sensors, catalyst differential pressure transmitter, and pre/post catalyst temperature transmitters. The design greatly increases the reliability and availability of the customer's engines, improving reliability. Concurrent with start-up
and commissioning, the operators and technicians were given hands-on training by
The largest obstacle for this project was that all components had to be rated for hazardous locations (Class I, Division II) without the use of a purge system or an explosion- proof enclosure. All components where located in a wall mountable enclosure which had lights for diagnostics. The HMI system provides monitoring functions in realtime for all six engines with one terminal on each of the two rigs.This was a very difficult andcomplicated job; complex issues had to be resolved on the spot to deliver a very unique project. GCS engineers built the E-3 panels and completed the installation successfully, exceeding the customer's expectations. CO emissions were reduced from 30,000 to 10 PPM CO per engine and engine efficiency was also improved on each engine/generator. This successful project has generated interest within the offshore network with requests to apply these systems at other location
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