FlexEnergy Turbines vs. Waukesha Engines

Leading oil and gas operators are increasingly turning to self-generation field power as a way to achieve multiple and sometimes competing objectives of maximizing uptime, reducing emissions, mitigating flaring, and keeping their asset development plans on track.

As operators move into regions not readily served by the utility grid, self-generation may be their only option. Once you move down the self-generation path, however, your choices boil down to traditional reciprocating engines or small gas turbines (sometimes called microturbines).

The need for reliable and clean emissions is also driving the trend of oilfield electrification, as operators look to maximize the power capacity without exceeding stringent emissions thresholds requiring expensive and time-consuming air permits.

A popular option is for many upstream and midstream operators are Waukesha gas engines. In this article, we compare and contrast the differences between Waukesha gas engines and small gas turbine-powered gensets from FlexEnergy Solutions.

Self-Generation Power Applications

In general, we find operators turn to self-generation for three main applications, including power for individual well sites, a grouping of sites (through their own microgrid), or centralized facilities in both the upstream and midstream sectors.

Self-generation in the oil and gas sector is often used to power:

Individual well sites
Large production pads
Centralized production facilities (tank batteries)
Produced water disposal facilities (SWD)
Microgrids serving multiple well sites/pads
Gas lift operations
Natural gas midstream facilities.

FlexEnergy Solutions Gas Turbines Vs. Waukesha Reciprocating Engines

Self-generation in oil and gas for oilfield electrification is dominated by two major options: generators powered by reciprocating engines or small gas turbines and microturbines.

Waukesha Gas Engines

Gensets using traditional Waukesha reciprocating engines, both natural gas and diesel-powered, are commonly used for self-generation. Waukesha reciprocating gas engines have been used in oilfields for decades. They are known for their reliability and slightly higher fuel gas tolerance (950-1,650 BTU HHV), at least compared to other reciprocating engines. Spare parts are widely available, and so are spare engines should a faulty unit need a replacement. As a reciprocating engine, however, they possess many of the drawbacks inherent to the design.

Pros:

This old technology is well understood.
Wide availability.
Diesel and natural gas-fueled options available.
Generally higher electrical efficiency than most turbines.

Cons:

Many moving parts and frequent maintenance requirements generally translate into lower uptime and reliability or the need for redundancy.
Higher emissions relative to alternatives (turbines).
May require secondary emission treatment solutions (e.g., SCR/Selective catalytic reduction) that are costly and maintenance intensive.
Diesel can be expensive and inconvenient (for diesel-powered options).
Can suffer from knock (autoignition) issues on high btu gases.

Small Gas Turbines and Microturbines

Natural gas turbines from FlexEnergy Solutions have been in common use for decades and are finding greater adoption in the oil and gas industry for self-generation options.

Pros:

Proven technology used worldwide in a variety of applications.
Few moving parts means very high reliability.
Very low emissions when compared to reciprocating engines.
Natural gas-fueled, providing beneficial use of tank vapors and waste gas streams.
Due to the significantly higher fuel gas tolerance turbines can mitigate flaring substantially by converting waste gas into clean power.

Cons:

Not as widely available as Waukesha reciprocating engine gensets.
Initial startup costs can be higher than reciprocating engine gensets, depending on the application and configuration.
Can be susceptible to derate, based on installed altitude and high ambient temperature; however, gas reciprocating engines derate more on high BTU gas compared to turbines.

FlexEnergy Solutions Vs. Waukesha Reciprocating Engine Gensets

Small gas turbines and microturbine powered gensets from FlexEnergy Solutions deliver several advantages over those using reciprocating engines from Waukesha Gas Engines (and other reciprocating engines), including:

Improved Reliability (Uptime). Once commissioned, you won’t see a technician for a year. The high reliability and few moving parts contribute to the highest uptime and reliability of the Flex Turbine microturbine and GT2000S, especially when compared to reciprocating engine generators, safeguarding continuous production and cash flow. The Flex Turbine requires only one eight-hour scheduled maintenance annually, typically completed in one shift. As a result, FlexEnergy Solutions turbines boast a 99.5% uptime track record.

Lowest Emissions Option (Better Than the Utility) The Flex Turbine is usually cleaner than most grid power options. Compared to nearly every utility power grid, FlexEnergy Solutions delivers the lowest emissions performance. In most cases, FlexEnergy Solutions offers the lowest emissions of any self-generation option.

Add More Power for Less Emissions on a Single Site. A lower emissions footprint means you can put more power on a single site while staying below certain emissions thresholds and avoid expensive and operationally restrictive Title V Operating permits. In a Case Study, independent tests confirmed that emissions of NOx (an ozone precursor), carbon monoxide, and NMNEHC at a facility powered by FlexEnergy Solutions’ GT2000S turbine generators were 15, 6, and 8 times lower than their respective permit requirements.

CASE STUDY: Decarbonizing Oil & Gas Production with Oilfield Electrification

Diesel Displacement. Using flare and vent gas produced on-site as fuel eliminates the emissions associated with transporting diesel to the facilities and provides a lower emissions power option than diesel- or natural gas-powered reciprocating engines.

Fast Service Response (We Are The OEM). Unlike many other self-generation providers, we are the Original Equipment Manufacturer. If you have an unexpected issue, there is no middleman; you will talk directly to the people who design, build, and maintain our turbines. That provides faster service response, efficient troubleshooting, and high reliability.

Contact Us Today

Contact FlexEnergy Solutions to learn more about our clean, dispatchable, and reliable field power solutions at sales@flexenergy.com or +1 (720) 826-0708.

Oil & Gas

FlexEnergy Solutions vs. Waukesha Engines – Alternatives to Recips