This autumn, the traditional report on the production activities of ENERGAS is timed to the tenth anniversary of the company. Noting this event, Energasovites rely on the achieved results and confidently look to the future. However, it is not in the rules of the team, even at the jubilee, to rattle into timpani. Not on that they stand here.

MAIN FACTOR OF DEVELOPMENT

In ENERGAS, they do not shy to compare their lived and professional experience with the wisdom of all humankind. Here, for example, they firmly learned this truth: to see the problem does not mean yet to understand and solve it.

To get to know the essence of the matter and then get a successful result - for Energasovites, this means to feel the whole complex of interrelated tasks for a specific project. Properly - in nuances and details to substantiate the optimal engineering solutions, correctly carry out design, evaluate the consequences of their decisions and systematically implement them.

The work practice of the first decade has repeatedly confirmed the correctness and inviolability of this approach. Laconically and capaciously, it is expressed in the motto of the company: "Attention to detail - from idea to implementation”. In this way, the resource of professional competence is growing year by year - the main factor in the development of this team. 

OPENING NEW DECADE

For 10 years of work in the segment of process equipment for gas treatment, ENERGAS has declared and established itself as a highly professional engineering corporation. Now it is a group of companies that, under a single brand, consistently carry out the design, production, supply, commissioning and servicing of packaged units and gas treatment systems for the oil and gas complex, electric power industry, machine building, chemical, construction and other industries.

Deep knowledge of production and engineering responsibility for the quality of their projects have become over these years the daily principles - the standard of life of the whole team.

Here there is accumulated a range of unique engineering solutions for the effective use of the latest generation process equipment at large power plants, small-scale power plants, autonomous power supply centers for industrial enterprises, APG gathering and transportation facilities, auxiliaries power supply complexes, special purpose facilities (gas turbine test benches and training centers).

With what results does ENERGAS open a new page of its work history? The team continues to actively enhance the unique organizational and engineering experience gained in the implementation of 135 projects in 35 regions of Russia and CIS countries. In general, since 2007, 269 gas treatment units have been commissioned or are preparing for launch. 

WHY THEY CHOOSE EQUIPMENT "ENERGAS"

Note that all projects are developed individually and implemented given the following features:

• special customer requirements;
• composition and quality of source gas;
• field of use;
• type and capacity of associated gas-using equipment;
• specificity of operation at the site;
• climatic conditions in the region.

Units necessarily pass preliminary (shop) tests with participation of representatives of the customer. All assemblies and elements are integrated as much as possible on a single frame, and the prefabrication level factor for the process equipment is 0.98, which together significantly reduces the period of construction, erection and pre-commissioning works.

All units are automated and equipped with their own control and monitoring systems (ACS) with data transfer function to the APCS of upper level. 

 
In the case where the equipment consists of several units, the local ACSs are combined into a group system. At the request of the customer, there are supplied operator's automated workplace and general control cabinet, which are located in the operator room of the facility.

The ACS carries out preparation for start-up, start-up, shutdown and maintenance of the optimum operation mode of the units; monitors process parameters; provides automatic protection; processes the parameters of the workflow and emergency events with the issuance of information on modern networks and protocols.

The most significant are also engineering solutions for regulating capacity of compressor units (CU). To control the flow rate of gas in the range 15 ... 100% of the nominal CU have the function of volumetric regulation through the spool valve of the compressor.

This method has a number of significant advantages:

1) CU operation does not depend on the change in gas pressure at the inlet, which is important in cases where the customer can not guarantee a stable gas pressure in the supply pipeline;

2) CUs have a high response rate to change in gas consumption;

3) when the capacity decreases, the power consumption of the engine decreases proportionally, which reduces the consumption of electricity for the own needs of the CU;

4) this type of regulation is fully automated and most effective in cost and operating costs in comparison, for example, with a method such as frequency control of the motor.

To change capacity in the range of 0 ... 15%, the CU is equipped with a bypass line that allows the units to operate in recirculation mode. This makes it possible to operate at zero flow during the adjustment period, as well as to react as quickly and correctly as possible to the change in the operating mode of the associated gas-consuming units.

Gas treatment and compression equipment is equipped with life support systems (heating, ventilation, lighting) and safety (fire detection, gas detection, alarm, fire extinguishing, detection of oxygen in the gas stream).

Depending on the climatic and operating conditions, the equipment has different versions of design:

• arctic;
• container;
• hangar (intra-shop);
• in easy-to-assemble shelter;
• on open frame;
• multi-module - with the integration of blocks into a single building with a common roof;
• multi-module - with block-boxes in their own separate shelters;
• combined. 

Inside the units, there is provided free space for quick and comfortable access to all the assemblies and elements, which ensures all-season and high-quality maintenance (maintenance, replacement of spare parts and consumables, repair, upgrade).

The main purposes of ENERGAS equipment are purification, compression and metering of treated gas volume. Accordingly, the main elements of gas treatment units are a filtration system with automatic drainage, a compression unit, a commercial (or process) gas metering unit.

Special design requirements of the customer determine the additional functionality - intake of peak fluid blowouts, smoothing out the pulsations of gas mixture, gas dehydration, removing heavy hydrocarbon fractions C5 and above, increasing the methane number, fine filtration, heating or cooling gas, reducing, determining the component composition and calorific value of gas; dew point temperature measurement.

In this case, P&ID includes special equipment that is built into the block-modules of the main units or is placed in an autonomous shelter:

• separator-slugcatcher;
• gas receiver;
• gas drying unit (ab- or adsorption, refrigerating, membrane);
• fine purification system;
• heater (electric or with intermediate heat-transfer agent);
• packaged boiler room;
• gas cooling unit (chiller);
• air cooler unit;
• single or multi-linear reduction terminal;
• flow chromatograph (calorimeter);
• dew-point temperature measuring system with a sampling device.

At the pre-start stage (after adjustment) there are performed: 1) own 24-hour testing; 2) checking the operability of units during 72-hour integrated tests of the facility; 3) training of the customer's personnel in the rules and norms of operation.

As a result, the confirmed coefficient of reliability of ENERGAS equipment is 0.98.

COMPLETED PROJECTS (10’2016 – 09’2017)

We name the most significant facilities at which ENERGAS in its jubilee year fulfilled the planned gas treatment projects.

Petroleum gas compressor station of Pyakyakhinskoye field ("LUKOIL-Western Siberia")

ENERGAS has installed and commissioned nine compressor units (CU, pictured left) in a variety of types and functions for operation as part of a petroleum gas compressor station (PGCS). These are: a low-pressure CU, four medium-pressure units, a CU for deethanization gas, three reciprocating units.

For the subsequent transportation, the booster compressor equipment performs post-treatment and compression of the associated gas of the 1-st and 2nd separation stages from the oil treatment unit, APG from the terminal separation unit, as well as gas from the unit of deethanization and stabilization of condensate.

To meter the volume of compressed gas, all units are additionally equipped with metering units with flow meters.

GTU-CHP of Centralnaya CHPP of St. Petersburg ("TGC-1")

At the site of PP-1 of Centralnaya CHPP, there was built GTU-CHPP on the basis of two power units. Each unit consists of a Siemens SGT-800 gas turbine unit and a heat recovery boiler. The total electric power of the GTU-CHPP is 100 MW, the thermal power is 100 Gcal / h.

Filtration, compression and feeding of fuel gas to the turbines is provided by process equipment - gas treatment unit and booster compressor station (BCS, photo 1) Enerproject consisting of three units.

All the work on put into operation of gas treatment system, including erection supervision, commissioning, own testing and integrated testing in the GTU-CHPP, was performed by the technical specialists of LLC “ServicENERGAS” (ENERGAS Group).

GTPP-84 of the Vostochno-Messoyakhskoye field (Messoyakhaneftegaz)

This northernmost mainland gas-turbine power plant in Russia includes six Solar turbines of the Titan 130 type, has a capacity of 84 MW and supplies electricity and heat to the facilities of the field.

The plant is equipped with fuel gas treatment unit (FGTU, photo 2) "ENERGAS". FGTU provides the necessary parameters of APG on purity, temperature, pressure and flow, which makes it possible to use associated gas produced at the field as main fuel for GTPP.

The basis of FGTU are: the compression package - four compressor units of hangar type, the filtration system - input coalescing scrubbers, the system of gas supply temperature regulation - a cascade of coolers and heaters.

FGTU is additionally equipped with a system for determining the temperature of gas dew point on water and hydrocarbons.

Center for Polytechnic Training (Surgutneftegas)

CPT operates in the West Surgut field (Khanty-Mansi Autonomous District). Every day, they are ready to accept up to 500 students here. You can obtain fundamental knowledge or improve your qualifications in 349 professions.

The center is unique not only in our country, but also in the world. It is equipped with simulators, computer labs and laboratories. Analogues of modern equipment operating at Surgutneftegas fields are installed at a special testing area.

A training compressor unit (photo 3) of the company ENERGAS functions as part of the test bed. This unit-simulator compresses atmospheric air in order to demonstrate process procedures during the gathering and pipeline transport of gas. CU operates in two modes - "training" and "examination".

At the CU inlet, an air treatment system is installed - a highly efficient separator similar to the inlet scrubbers for gas filtration, which equip the units at the Surgutneftegas facilities.

PWRU-3 of Sovetskoye field (Tomskneft)

At the preliminary water removal unit, ENERGAS vacuum compressor station (photo 4) operates, which ensures the rational use of low-pressure APG at the site in the maximum possible volumes.

The screw-type VCS compresses associated gas from the second separation stage from a pressure close to vacuum (0.001 ... 0.01 MPa) to gas pressure of the first separation stage (0.6 MPa) for co-feed into the pipeline to the gas distribution station.

According to the project, the VCS operates with a minimum capacity of 250 m3 / h. Earlier, the ENERGAS Group commissioned vacuum compressor stations at two other facilities of Tomskneft: PWRU-9 of the Sovetskoye field and PWRU-5 of the Vakhskoye field.

GTU-26.5 of Mogilevskaya CHPP-1, Republic of Belarus (Mogilevenergo)

In the course of the upgrade of Mogilevskaya CHPP-1, a modern power unit was put into operation at the facility, based on the LM2500 + (GE) gas turbine unit with a capacity of 26.5 MW.

Fuel for GTU is natural gas. Its treatment and feeding to the turbine is provided by the gas treatment unit of ENERGAS (photo 5):

- BCS of two modular units for compressing gas to the required operating pressure;

- filtration system of two separators (filter-scrubbers) integrated in the CU block-modules;

- underground drainage tank for collection and removal of condensate and sludge.

Fields of Bolshekhetskaya Depression ("LUKOIL-Western Siberia")

One of the priority tasks of LLC “LUKOIL-Western Siberia” is the development of the Bolshekhetskaya Depression fields (Yamalo-Nenets AO) - a region with proven high oil and gas potential.

Simultaneously, the problem of rational use of associated gas is being solved here. The transport system of liquid hydrocarbons from the fields of the Bolshekhetskaya Depression is equipped with a compressor station that purify and pumps low-pressure APG from the end separation unit.

CS of ENERGAS in the Arctic version is designed for operation in severe climatic conditions. The additional functionality of the station is metering of compressed gas.

Autonomous power supply center of microelectronics factory OJSC “Angstrem-T”

For the research and production complex of the microelectronics factory Angstrem-T (Moscow, Zelenograd), its own power supply center was built - an autonomous gas reciprocating power plant with a capacity of 36 MW and a boiler house. The GRPP includes five bi-fuel units Wartsila 16V34DF, operates on a trigeneration cycle and provides the company with the necessary volumes of electricity, heat and cold.

Gas fuel for the energy center comes through a multifunctional gas treatment system (GTS, photo 6) of ENERGAS, which consists of the following equipment: an input filters unit, a gas metering station, a fine purification system, two gas compressor units, an in-site gas pipeline.

The process complex carries out preliminary filtration, flow metering, fine purification and compression of gas.

Construction of GTS "on a turn-key basis", including erection supervision, commissioning, individual testing and integrated testing in the power plant, as well as training of the customer's personnel was conducted by specialists of the ENERGAS Group.

BCS at the Alan field (Uzbekneftegaz)

The booster compressor station based on two gas-compressor units GPA-16 "Volga" was built by JSC "KMPO" for the project of development of the gas field "Alan" in the south of Uzbekistan.

The BCS includes a gas treatment system. The process unit (photo 7) includes two high-efficiency separator filters, a condensate drain assembly, electric gas heaters, bilinear reduction units.

The system provides gas-pumping units with fuel and start-up gas with the necessary parameters for purity, temperature, pressure and flow. The degree of filtration from mechanical impurities and droplet moisture is 99.98%.

The equipment was supplied by the company ENERGAS, erection supervision and technical support of the project were carried out by ServicENERGAS.

GTU-CHPP at the Yaregskoye field – power supply complex "Yarega" ("LUKOIL-Komi")

At oil & titanium field there is built an auxiliaries power supply complex. The electric power of the GTU-CHPP is 75 MW, the thermal power is 79.5 Gcal / h. Fuel for the power supply complex "Yarega" is natural gas of the Kurino-Patrakovskoye gas condensate field.

The design parameters of gas are provided by the multifunctional gas treatment system "ENERGAS" (photo 8): a gas treatment packaged unit (GTPU) and booster compressor station (BCS).

GTPU is equipped with a filtration unit, a drainage system, a gas metering unit, a reduction system. The main purpose of GTPU is flow metering and gas purification. Additional functional is stabilization of pressure.

The BCS compresses treated gas to 4.5 ... 5 MPa and feeds it to the GTU-CHPP turbines. It consists of four screw-type compressor units.

For the effective monitoring, control and safe operation of this process equipment, the ACS of gas supply system is responsible. It includes local ACS of the units, general control cabinet, operator's workstation, emergency shutdown control panel.

PROJECTS AT IMPLEMENTATION STAGE

Today, at various stages of readiness for launch (factory tests, delivery, erection, commissioning, pre-start testing), there are also 35 gas treatment and compression units.

Vostochno-Urengoiskoye field (“Rosneft”). At the site of gas and condensate processing plant there is installed a multi-module fuel gas treatment unit of ENERGAS. FGTU of 8 modules will provide gas supply for more than 10 facilities. Among them there is a gas turbine power plant, a low-temperature separation unit, a boiler room, a condensate stabilization unit, a low-pressure booster compressor station, a methanol recovery unit etc.

Test bench of gas turbine engines (UMPO). At test bench there are tested GTE type AL-31ST. As part of the upgrade, the facility is equipped with a booster compressor unit, designed to supply the test turbines with fuel gas with the necessary parameters.

GTPP of Yuzhno-Nyurymskoye field (“Surgutneftegas”). At the auxiliaries power plant under construction there is prepared for commissioning BCS of hangar type, which is designed to treat and feed associated gas to turbines.

CHPP “Vostochnaya”, Vladivostok ("RAO ES of the East"). For the gas turbine power units of the new plant, the gas treatment system of ENERGAS is installed. Process equipment includes three two-stage CUs, a gas treatment unit and a gas receiver.

CPF of Vostochno-Messoyakhskoye field (“Gazpromneft-Razvitie”). Here ENERGAS is implementing a project for the putting into operation of two CUs for compression of APG of the final stage of separation and gas from Cenomanian water.

PWRU-4 of Vakhskoye field (“Tomskneft”). At the preliminary water removal unit there is carried out pre-start preparation of vacuum compressor station for gathering and transportation of low-pressure (0.001 MPa) APG.

GTPP of Verkhnekolik-Eganskoye field (“Rosneft”). Feeding of APG to GTPP-24 MW turbines will be carried out by the fuel gas compression unit of ENERGAS. The FGCU is housed in a separate building, includes a gas treatment unit and a compressor unit of four compressor units.

CHPP of the National Research University "MEI", Moscow. According to the reconstruction project, a 10 MW CCGT unit is being created here. The new combined-cycle power unit will receive gas from the CU supplied by ENERGAS.

GTU-TPP at the site of the central boiler-house in Elabuga. The gas treatment system, consisting of BCS and PGTU, will provide high-quality fuel gas to the new power unit based on four GTU Turbomach.

CSLSS of Yuzhno-Vatlorskoye field (“Surgutneftegas”). As part of the compressor station of low separation stages, two CUs for gathering and transporting associated gas from the facilities of a number of fields will operate.

Groznenskaya TPP. ENERGAS specialists will perform the whole cycle of pre-start operations at the fuel gas BCS for two Siemens turbines SGT5-2000E.

Pregolskaya TPP, Kaliningrad. Integrated fuel gas treatment system supplied by ENERGAS is designed to supply turbines of four combined-cycle power units with a unit capacity of 110 MW that will form the basis of a new power plant.

It is important to note that the main focus of the ENERGAS Group is always on comprehensive maintenance of gas treatment and gas supply equipment.

INCREASED ATTENTION - TO THE DEVELOPMENT OF SERVICE

As of September 2017, the total operating time of existing units of ENERGAS was more than 8,000,000 hours. Naturally, for normal operation and full development of the specified life of process equipment, timely service is required (photo 9), and if necessary - upgrade, current or major repairs.

The solution of the tasks of ensuring the guaranteed reliability and efficiency of the gas treatment and gas feeding equipment supplied by ENERGAS and other producers is within the competence of ServicENERGAS.

The service process is based on the organizational and engineering experience accumulated in the implementation of 135 energy and oil and gas projects - practically throughout Russia and abroad. The geographical scale is from Sakhalin to Kaliningrad. Gas processing facilities created by ENERGAS operate in the Far East, and in Yakutia, in Siberia, in the Far North, in southern and central regions, in Moscow and St. Petersburg, as well as outside the country - in the Republics of Belarus and Uzbekistan.

That is why the increased attention in the service activities of the ENERGAS Group is paid to the remote monitoring system. This system is designed to ensure continuous monitoring of the state of equipment and process procedures by specially trained employees and experts of ServicENERGAS.

As a result, the necessary organizational and engineering solutions are made in a timely and qualified manner. And what is especially important, these solutions are developed on the basis of relevant and reliable data coming directly from the facility. These materials are interpreted on-line, comprehensively analyzed and professionally modeled.

Over a year, a special program for the provision of long-term service is being implemented. It consists of long contracts (up to 36 months) for post-warranty maintenance of gas treatment and compression units.

In general, ServiceENERGAS carries out the entire range of maintenance works:

• preparation of equipment for start-up;
• maintenance during the warranty period;
• service support in the post-warranty period;
• upgrade;
• current (local) repair;
• overhaul with dismantling of equipment;
• supply and replacement of spare parts, components and consumables;
• technical advice and training.

CONCLUSION

Each successfully implemented project is not only a concise paragraph in the official production report or a vivid report on the television screen. This is always a landmark life event. Over the past ten years, ENERGAS specialists have firmly grasped: without the human soul, concentration of experience, strength and will, even the outstanding engineering design will remain only a "lifeless" sheet of paper.

Therefore, human capital has always been, is and will be the main component of the fuel and energy complex of Russia - a guarantee of practical implementation of the most daring technological forecasts and projects.

In its new decade, the team of ENERGAS enters, actively strengthening professional and cooperative ties in the segment of integrated gas treatment equipment. Being well aware of the importance of such cooperation, the energy people express great gratitude to all colleagues and partners in joint work.

Specialized magazine "Turbines & Diesels"