ENERGAS gas-control station will provide fuel for the direct oil heating furnaces at oil treatment plant Usa-Heavy Oil

19 August 2020

As part of the technical re-equipment of oil treatment plant at Usinsk field (OTP Usa-Heavy Oil, LUKOIL-Komi), the facility is being equipped with a block-type gas-control station (BGCS) produced by ENERGAS.

BGCS is multifunctional complex intended for the gas purification, heating, and reducing to stable design parameters before it is fed into a direct oil heating furnaces. The functionality of the process unit also includes flow measurement and gas quality control.

The main elements of the ENERGAS BGCS:

- Highly efficient gas filtration system with two-stage coalescing filters;
- Commercial metering unit with turbine flow meters;
- Gas heating unit based on explosion-proof electric gas heaters with a device for smooth regulation and heating blocking;
- Two-line reducing system;
- Output gas quality control unit with dew point analyzer, manometer and thermometer, pressure and temperature sensors.

Filtration efficiency is 100% for the liquid fraction and 99.9% for solid particles larger than 2 μm. The gas pressure is reduced from 1.6...2.5 MPa to 0.6 MPa. The designed outlet gas temperature is +25°C. The maximum capacity of the station is 21,360 Nm3 / h.

The multifunctional complex is placed in a separate weatherproof module and is equipped with the necessary engineering systems, including life support systems (heating, ventilation, and lighting) and safety (fire detection, gas detection, and alarm).

BGCS workflow is fully automated. The control system is made on the basis of microprocessor technology, using modern software and connection equipment. The local ACS will be integrated with the automated processes control system of facility.

Gas treatment equipment was supplied with a high degree of prefabrication (availability factor of 0.98+), what significantly reduces the commissioning time. The coefficient of technical use is 0.92+; coefficient of reliability of starts is 0.95+.

The installation of the gas-control station at operation site is scheduled for September this year. The entire cycle of pre-launching activities (erection supervision, adjusting, own and integrated tests, staff training) will be performed by the specialists of ServicENERGAS, a member of the ENERGAS Group.


The commissioning in 2009 of the oil treatment plant Usa-Heavy Oil opened a new page in the history of LUKOIL-Komi LLC. This OTP has become the largest launch facility for the company since its creation. The design capacity of the plant is about 11 million cubic meters of liquid fraction and 2 million tons of oil per year, and the tank battery is about 32 thousand cubic meters.

Usa-Heavy Oil is considered unique in Russia – this is the first facility of such capacity, designed to treatment highly viscous "black gold". The project completed the separation of the flows of "light" and "heavy" oil at the Usinsk field. With the launch of the OTP, the oil gathering system of this production field was also reconstructed.

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