ENERGAS – 15 years in the field of process equipment for gas treatment

On September 24, ENERGAS celebrated its 14th anniversary. This year opened a period of tough professional tests for the company – for willpower, organizational commitment, professional significance and the demand for engineering experience.

ENERGAS employees respond to the challenges of the time by timely and high-quality implementation of gas treatment projects for various facilities in the electric power industry, oil and gas complex and gas-consuming enterprises.


At first, let's clarify the results. Since 2007, ENERGAS has supplied a total of 320 units for gas treatment and compression. In the electric power industry, our process equipment provides fuel for 230 gas turbines and gas-reciprocating units with a total capacity of over 6.7 GW. In the oil and gas industry, ENERGAS units carry out treatment of natural and associated gas at 63 facilities in 47 fields.

ENERGAS builds up unique experience in compressing low-pressure APG. In total, 126 compressor units are involved in this segment, pumping gas with an inlet pressure range of -0.02 to 0.4 MPa. In this case, 57 machines operate at gas gathering and transportation facilities, and 69 units prepare APG as fuel for the power supply complexes of the fields.

The geography of ENERGAS' team work is expanding. A number of projects have been completed in Belarus, Kazakhstan, and Uzbekistan. In Russia, ENERGAS equipment prepares various types of gas everywhere - from Sakhalin to the Kaliningrad Region, including the leading oil and gas producing regions - the Tyumen Region, the Republic of Sakha (Yakutia), the Far North.

ENERGAS has the production, comprehensive commissioning and maintenance of 320 gas treatment and compression units for facilities in the oil and gas complex, electric power industry and industrial enterprises.

The team was celebrated its 15th year of activity with thirteen significant projects that use special engineering solutions devised to meet the special requirements of customers, operating conditions, and the composition of the source gas incoming for comprehensive treatment and compression. Here are some examples.


The factory power supply complex of the new HAYAT enterprise was equipped with the ENERGAS system for the comprehensive treatment of fuel gas

HAYAT Russia is increasing its production capacities – a large plant for the production of sanitary and hygienic paper products was built at the Borovsk site of the Kaluga special economic zone.

Here, an autonomous (decentralized) power supply complex is also being created to supply production with its own energy resources. Electricity will be generated by the two SOLAR Mars 100 gas turbine unit (GTU) with an installed capacity of 10 MW each. The production of high-potential process steam will be provided by the two waste heat boilers with a productivity of 15 t / h each. In addition to the cogeneration power unit, the structure of the power supply complex includes an auxiliary gas boiler house.

One of the most important factors contributing to the reliable and efficient operation of generating equipment is the quality of fuel gas. The supply of the GTU and boiler house with fuel with the specified parameters in terms of purity, temperature, pressure and flow rate will be guaranteed by the ENERGAS multifunctional system – a block-type gas treatment station (BGTS) and a booster compressor station (BCS).

BGTS with a throughput of 9,317 m3 / h is used for metering, filtration, pressure reduction and quality control of gas. This process unit has been put into operation and at this stage (before the GTU launch) provides fuel to the boiler house of power supply complex.

Station is equipped with coalescing filters, the purification efficiency is 99.9% for solid particles larger than 3 microns and 100% for droplet moisture. In the BGTS, the purified gas will be divided into two flows. The first one is directly headed to the BCS and then to the GTU turbines, the second flow passes through a reduction system, which reduces the gas pressure and stabilizes it at the 0.3 MPa level required for feeding to the boilers.

At BGTS there is measured total volume of gas supplied to the power supply complex (commercial metering) and separately measured volume of fuel for the boiler house (process metering). Metering units made based on flow meters of ultrasonic type.

The gas treatment station is placed in a separate all-weather block-box, equipped with systems of working and emergency lighting, heating and ventilation, safety systems. BGTS is fully automated, the local control system is integrated into APCS of facility.

The booster compressor station, which is part of the ENERGAS system, is intended to compress the fuel treated in the BGTS and feed it to the turbines at a pressure of 2.6 MPa. The maximum volume capacity of BCS is 6,336 Nm3 / h, gas flow rate depends on the load of the GTU and is controlled in the range from 0 to 100% by a special two-circuit regulation system.

The process flow scheme of the BCS guarantees stable maintenance of the design fuel temperature necessary for the normal operation of turbines. The delivery line of the station is equipped with a heat exchanger that cools the working medium and ensures the optimum gas supply temperature (up to +70°C) set by the GTU manufacturer and terms of the project.

Taking into account the stringent requirements for the purity of fuel gas, the basic filtration system of the BCS, consisting of gas-oil separator and coalescing filter of the 1st and 2nd stages of purification, is enhanced due additional elements: 1) a protective strainer is installed on the suction line of the compressor station; 2) a safety filter for fine purification of gas is built into BCS module. Eventually, the content of impurities in the fuel at the inlet to the GTU shut-off valve block does not exceed 0.1 ppmw (mg / kg).

Gas-booster unit is housed in its individual shelter equipped with life support systems. According to safety requirements, BCS is equipped with fire detection, gas detection, alarm, and fire-extinguishing systems.

At present, the compressor station has been mounted at the operational site of new HAYAT enterprise; adjustment of equipment is planned. The BCS was supplied in maximum factory readiness what significantly reduces the duration of the pre-start works.

Peak-standby energy sources in Belorussia obtained four ENERGAS gas receiving stations

In the Republic of Belarus, the peak-standby energy sources (PSES) based on Siemens SGT-800 turbines is being created. At the Minsk CHPP-5, this is a 300 MW GTPP consisting of six turbines, at the Berezovskaya SDPP – 250 MW GTPP (of five turbines), at the Lukomlskaya SDPP – 150 MW GTPP (of three turbines), at the Novopolotsk CHPP – 100 MW GTPP (of two turbines).

The ENERGAS Company has equipped the Belarusian PSESs with four gas receiving station. GRSs were manufactured by ENERGAS under the special projects and are the gas treatment stations which will provide the specified design parameters of the fuel before it is fed to the turbines. The main purpose of GRSs is purification, flow measurement and heating of gas.

All the stations are equipped with a separation system with coalescing filters-scrubbers. The efficiency of gas purification is 99.9% for impurities over 10 microns in size. It is possible to quickly replace the filter-elements.

To measure the volume of fuel entering the gas-turbine power units, the GRSs are equipped with the two-line commercial metering units. Data from them is transmitted via communication channels to the upper level of the automated process control system.

To achieve design gas temperature (up to +40°C), at each GRS there is installed heating module, which composed of heat exchangers and subassembly of gas condensate gathering and storage with a drainage tank.

The process units are equipped with fuel quality control assemblies installed on the outlet pipelines and equipped with measuring and analytical equipment.

The stations are placed in sound- and heat-insulated block-boxes and equipped with necessary engineering systems. GRSs were designed to operate in automatic mode, their throughput is from 29,210 to 87,506 m3 / h, depending on the number of conjugated turbines and the capacity of the PSES.

Technical support for all projects is provided by ServicENERGAS, a member of the ENERGAS Group. Service engineers perform an entire cycle of pre-start activities: installation supervision, adjustment, in-house and integrated testing, and staff training.

ENERGAS provided the main equipment for the reconstruction of the gas distribution station Beloozersk-2

Berezovskaya SDPP (RUE Brestenergo) is one of the largest enterprises of the electric power industry in the Republic of Belarus. The power plant ensures the generation and supply of electricity to the country's power grid, as well as heat supply to the industrial enterprises and the housing and communal sector of the city of Beloozersk. At present, the installed electric capacity of the SDPP is 1,095 MW.

By reason of the planned growth in fuel consumption, the external gas supply scheme is being upgraded here - the construction of a high-pressure supply pipeline and the reconstruction of the gas distribution station (GDS) Beloozersk-2 is being carried out. The reconstruction involves dismantling the existing gas purification unit, installing a new gas filtration system, and increasing the design capacity of the GDS to 145,200 Nm3 / h.

The filtration system, manufactured and delivered to the facility by the ENERGAS, is intended to remove solid particles and moisture from high-pressure (3.1 ... 5.4 MPa) main gas and consists of three filters-separators with a throughput of 72,600 Nm3 / h each. The system includes two working lines and one reserve.

Required gas purification is provided in two stages – due to the use of the gravitational principle and combined filter elements. In this case, the efficiency is 100% for impurities larger than 50 µm (microns); the content of impurities in the gas at the outlet does not exceed 1 mg / m3.

At Aktobe CHPP in Kazakhstan, the ENERGAS system for fuel supply of a new gas-turbine power unit is being prepared for operation

The Aktobe Central Heating and Power Plant is the only source of district heating in Aktobe, the largest city in Western Kazakhstan. The electric and thermal capacity is 118 MW and 878 Gcal / h, respectively.

The new gas-turbine power unit (GTU) with a designed capacity of 57 MW is being integrated into the process flow scheme of the facility to operate in a combined cycle. The main generation will be provided by a Siemens SGT-800 industrial gas turbine.

From turbine, exhausted hot gases (fuel combustion products) will flow into the waste-heat boiler manufactured by JSC Machine-Building Factory of Podolsk to generate steam with a pressure of 3.0 MPa and a temperature of 420°C in an amount of 70 tons per hour. The resulting superheated vapour of medium pressure is sent to the existing steam turbines of Aktobe CHPP for secondary electricity generation.

To fuel supply for power unit, the ENERGAS comprehensive gas treatment system is intended, which will provide the quality of fuel in accordance with the design parameters. The main elements of this system are a block-type gas treatment station and booster compressor station.

BGTS is used to purify, reduce and stabilize the pressure, measure the volume of entering gas. The station is equipped with a filtration unit, a reduction module, and a subassembly of process metering. The throughput of the BGTS is 15,433 m3 / h – similar to the rated fuel consumption of GTU.

After preliminary treatment, the gas flow is directed to the BCS, which consists of two booster units with a capacity of 12,000 kg / h each, designed to compress and feed fuel to the SGT-800 turbine at a pressure of 3.1 MPa and a temperature of +60°C.

Gas treatment station and booster compressor station are fully automated. Their control systems are made based on microprocessor technology, using modern software, switching equipment, channels and protocols of communication. The local ACSs are being integrated with the facility's APCS. They provide remote control of units, and automatic protections and alarm; they monitor the process parameters and indoor gas hazard, handle the parameters of the workflows and emergency events, issue information to the operator panel.

Commissioning of the gas treatment and fuel supply system for the new GTU at Aktobe CHPP – erection supervision, starting-up and adjustment, own and integrated tests as well as training of operational personnel are carried out by the specialists of ServicENERGAS (ENERGAS Group).

ENERGAS has supplied a multi-unit gas-control station for gas supply to the Zainsk area of Tatarstan

Gas-control station (GCS) is a gas treatment facility and consists of several block-modules with equipment for various purposes, docked into a single building. ENERGAS GCS is used for purification, odorizing, pressure reduction, and flow measurement of gas.

The maximum throughput of the facility is 100,000 m3 / h. GCS will provide consumers in the city of Zainsk and the Zainsk area with gas with a pressure of 0.3 MPa and 0.6 MPa, respectively.

The main elements of multifunctional process complex:

- Gas filtration system with an efficiency of 99.9% for impurities larger than 10 microns;
- Automatic odorizing subassembly with a tank for odorant storage and issuance;
- Two commercial metering units (for gas of 0.3 MPa and 0.6 MPa);
- Two pressure reduction and stabilization modules (0.3 MPa and 0.6 MPa);
- Gas quality control subassembly with measuring and analytical equipment;
- Automated control system.

Novopolotsk CHPP obtained highly efficient ENERGAS gas filtration system

This process equipment is intended to ultrafine purification of gas fuel at the inlet to the shut-off valve block of SGT-800 turbines. ENERGAS end system of filtration consists of four filters of vertical cartridge type with a throughput of 14,890 Nm3 / h each.

Filtration efficiency is 99.9% for particles larger than 0.01 microns. As a result, the residual content of impurities in purified gas does not exceed 0.001 ppmw (mg / kg). Coalescing filters are equipped with pressure differential sensors that signal the contamination of replaceable elements. The signals go directly to the upper level of the APCS.

The new, 16th year of ENERGAS' work in the field of comprehensive gas treatment has begun. The company's team, as before, focuses its efforts and experience on engineering creativity and high-quality execution of design and technological requirements of customers.

Industry-specific magazine "Neftegaz.RU"

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