PRODUCT CATALOGUE · 2019-06-21 · 9001:2008. In 2008 we were the first company to obtain...

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P R O D U C TC A T A L O G U E

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Company Profile ............................................................................................................. 6

KOSMOS-NEFT-GAS TECHNOPARK .................................................................................... 8

KOSMOS-NEFT-GAS Service Company .............................................................................. 10

Slug Catcher / Separator Skid .................................................................................................................... 11

Gas Separator Skid With «Gas-Gas» plate type heat exchangers .................................................................12Gas Separators ........................................................................................................................................14Fuel Gas Treatment Skid ...........................................................................................................................16Air Compressor Skid ................................................................................................................................18HP Membrane Type Nitrogen System ........................................................................................................19Well Automation Skids ..............................................................................................................................20Well automation skid МОС2/1-11 with standalone power supply for electrically driven X-mas tree valves ........22Well automation skid МОС2/1-04 for concentric tubing wells .......................................................................24Pipeline Manifolds and Valve Blocks ..........................................................................................................25

Control Systems ....................................................................................................................................... 26

Offshore control systems ..........................................................................................................................32Inhibitor Injection Unit ...............................................................................................................................34Gas Distribution Plants .............................................................................................................................36Gas Dehydration Units ..............................................................................................................................38Smokeless Flare ......................................................................................................................................40Flare Ignition Complexes ..........................................................................................................................42Mobile Vertical Stack Flare .......................................................................................................................43Horizontal burners for well blowing products ..............................................................................................44Horizontal combined burners ....................................................................................................................46Horizontal burners for gathering line blowing gas ........................................................................................48Horizontal burners to burn process drains at oil, gas and gas condensate fields ............................................49Atmospheric Burner Units .........................................................................................................................50Atmospheric Burners ...............................................................................................................................51Nozzle burners ........................................................................................................................................52

Weatherproof Enclosures .........................................................................................................................53

Offshore Flare .......................................................................................................................................... 54

Offshore Thermally Controlled Containers for Transportation and Storage of Chemicals ................................56

Heater type 350 .......................................................................................................................................58Heater type 500-01 ..................................................................................................................................59Heater type 500-02 ..................................................................................................................................60Heater type 1000 .....................................................................................................................................61Air Heater ................................................................................................................................................62Steam Generator .....................................................................................................................................63

Valves .....................................................................................................................................................64

Quick-Detach Restriction Device ...............................................................................................................68

Valves .....................................................................................................................................................69

Hydraulic Pressure Intensifier type M4, M7 ................................................................................................70

Downhole Equipment ...............................................................................................................................71

Sampling Devices ....................................................................................................................................72

Ball valve hydraulic actuators ....................................................................................................................74

Hydraulic isolation valve ............................................................................................................................75

Pneumatic plunger type pump unit ...........................................................................................................76

Equipment for Nuclear Power Industry .......................................................................................................77

Blender ..................................................................................................................................................80

Granular Component Unit ........................................................................................................................82

Flare control unit ......................................................................................................................................84

High voltage unit .....................................................................................................................................85

“KNG ICS” Integrated SCADA/HMI system for automated process control, utility metering and production control ...................................................................................................................................86

Local Control Panel LCP2-1 ......................................................................................................................88

19” BOX IPCP-01 with Hirschman Equipment and IP ...................................................................................90

LV Switchgears ........................................................................................................................................92

Air Cooler Automatic Control System .........................................................................................................94

Contactless Torque Meter For 2-32 MW Gas Compressors .........................................................................96

Contactless Torque Meter ........................................................................................................................97

Lightning Protector M-200 ........................................................................................................................98

Alternative Power Sources ......................................................................................................................100

INNOVATION: Air Turbine Unit .................................................................................................................101

Posts of emergency communication and heating ......................................................................................102

Emergency Voice System .......................................................................................................................103

Stand-alone power supply complex .........................................................................................................104

Weatherproof Cabinets for various equipment ..........................................................................................106

Independent Power Supply Sources Solutions based on free piston engines (Stirling engines) .....................108

Contents

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Dear partners,

Let me proudly present our catalogue containing a brief overview about our company and the products.

The KOSMOS-NEFT-GAS HOLDING is an enterprise dedicated to the development of integrated solutions, manufacturing and supply of a wide array of equipment for hydrocarbon and chemical industries, as well as for Russian and CIS nuclear power plants.

A state-of-the-art technical infrastructure of the proprietary production complex, highly qualified and experienced staff, contribute significantly towards the final product in terms of quality and technical characteristics, which allows Kosmos-Neft-Gas Holding to compete with leading foreign manufacturers.

The subdivisions of the KOSMOS-NEFT-GAS HOLDING such as the Scientific & Engineering Centre and the “Hydrocarbon Processing Project” institute are constantly interacting with leading Russian R&D organizations, which allows the company to offer unique and innovative technologies in order to make production and processing of oil, gas and gas condensate recovery viable.

Our service subdivision provides a full range of services for equipment installation, warranty and post-warranty maintenance, as well as training to specialists at installation and production organizations.

The products of the KOSMOS-NEFT-GAS HOLDING are well known in the market and have arguably proved to be reliable, easy to operate and environmentally friendly.

Let me express my sincerest appreciation to our partners for their confidence in the company’s products and I look forward to furthering a mutually beneficial cooperation.

Yours faithfully,

Ivan G. LachuginPresident

KOSMOS-NEFT-GAS HOLDING

Our partners:

Gazprom dobycha astrakhan (russia)

Gazprom dobycha urengoy (russia)

Gazprom dobycha nadym (russia)

Gazprom dobycha Orenburg (russia)

Gazprom dobycha Yamburg (russia)

Gazprom dobycha noyabrsk (russia)

nOVateK (russia)

rosneft (russia)

atomenergoproekt (russia)

Gazprom transgaz Moscow (russia)

saratovneftegaz (russia)

nizhnekamskneftekhim (russia)

Yamal spG/LnG (russia)

achimgaz (russia)

YarGeO (russia)

sibneftegaz (russia)

arktikgaz (russia)

rn-snabzhenie (russia)

samaraneftegaz (russia)

udmurtneft (russia)

Vostsibneftegaz (russia)

Volgodeminoil (russia)

Gazpromneft-noyabrskneftegaz (russia)

Gazpromneft-Vostok (russia)

Irkutsk petroleum Company (russia)

LuKOIL-Zapadnaya siberea (russia)

sIBur Innovations (russia)

sibur-Khimprom (perm, russia)

sibur tyumen Gaz (russia)

novy urengoy Gas Chemical Complex (russia)

plastik (uzlovaya, russia)

severneftegazprom (russia)

sevmash (russia)

arsenal Group (russia)

procter & Gamble-novomoskovsk (russia)

ZapsIBGaZtrans (russia)

LuKOIL-nizhnevolzhskneft (russia)

Norway

Great BritainGermany

Italy

St. Petersburg

LithuaniaBelarus

MoscowKazan

Voronezh

Bulgaria

Volgograd

ShakhtyAstrakhan

Yamal

Nadym

Surgut

NefteyuganskPerm Tyumen

UfaSamara

OrenburgKazakhstan

Pyt-Yakh

Norilsk

Novy Urengoy

Tarko-salee

MegionNizhnevartovsk

Tomsk

Ust-Kut

IrkutskSaratov

General structure of the company

The KOSMOS-NEFT-GAS holding company was established in 1994.

The holding includes:

• Scientific & Engineering Centre KOSMOS-NEFT-GAS – research and development works to develop process equipment for oil and gas and nuclear power industries.

• Hydrocarbon Processing Project KOSMOS-NEFT-GAS – an engineering institute to carry out comprehensive designing of chemical, petrochemical, oil and gas facilities.

• Production Complex KOSMOS-NEFT-GAS – trial, low volume and serial production in accordance with specifications issued by the Scientific & Engineering Complex, Hydrocarbon Processing Project and customer provided.

In 2006 the KOSMOS-NEFT-GAS Service company was established.

The HOLDING is a coordinator of the Voronezh Regional Cluster of Oil, Gas and Chemical Equipment Manufacturers. The cluster was established in 2009 and it currently includes 36 enterprises of the region manufacturing the processing facilities for such leading companies as Gazprom, Rosneft, LUKOIL, NOVATEK, SIBUR Holding, etc.

Exhibitions of cluster equipment associated with visits of above mentioned companies are hold annually at the Production Complex premises.

Activity

• Engineeringfacilitiesofchemical,petrochemical,oilandgasindustries,developmentandconstructionofhydrocarbonfields

• Manufacturing of equipment for production, transportation, processing of oil and gas, equipment for petrochemical andnuclear power industries

• Engineeringandintegrationofautomatedprocesscontrolsystems

• “Turnkey”equipmentsupplyandinstallation

• Warrantyandpostwarrantyservicing

Certification

The quality assurance system of the KOSMOS-NEFT-GAS HOLDING is certified in accordance with the requirements of ISO 9001:2008. In 2008 we were the first company to obtain GAZPROM’s corporate quality control certificate STO 9001 – 2006.

All products manufactured by KNG are enclosed with certificates of conformance, approving documents and are designed in strict accordance with customer’s specifications. All supplied equipment is warranty guaranteed.

Company Profile

Com

pany

Pro

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The TECHNOPARK was established by the KOSMOS-NEFT-GAS in 2006. In 2008 it was awarded the Technology Park Status in accordance with the Law of Voronezh region 43-OЗ dated June 5, 2006 “On technology parks in Voronezh region”.

The strategic objectives of the TECHNOPARK are as follows:

• stimulatingdevelopmentofsmall and medium manu-facturing businesses;

• assisting in innovation-based development of the region.

• increasing profit and effi-ciency of the TECHNOPARK assets, launching new technologies, products and services.

The Financial & Industrial Company KOSMOS-NEFT-GAS as a basic enterprise has provided more than 150,000 sq.m. of production, office and service premises for the TECHNOPARK development occupying the area of 18,5 hectares.

Main activities of the TECHNOPARK are as follows: - the development and manufacturing of new equipment types for oil & gas and chemical industries.

Main objectives of the TECHNOPARK activity are as follows:

• scientificresearchanddevelopment,introductionofscientificactivityresultsintoproduction;

• creationanddevelopmentofnewhigh-endtechnologiesandmanufacturingofexportedandimport-substitutinggoods;

• jobcreation,qualificationimprovementofinnovationenterprisemanagers,expertsofhigh-endproductionfacilitiesandorganization of innovation activity;

• reductionoftimeforimplementationofinnovativeprojects;

• provision of better conditions, in comparison with the average ones in the region, for economic activity of smallmanufacturers;

• establishmentofproductionandscientificrelationsbetweenmajorindustrialenterprisesandsmallhigh-endbusiness.

Superb technical equipment of the TECHNOPARK production complexes, high professional level of the employees and resident companies make it possible to create a wide spectrum of complicated, but reliable products for the leading Russian and world consumers of advanced technology equipment.

First of all, the TECHNOPARK sees itself as a pilot plant base for new technologies, which is able to implement the results of the fundamental and applied research into specific devices for oil and gas industry.

KOSMOS-NEFT-GASTECHNOPARK

In order for the KNG products to compete with the world analogs, a strong cohesion of science and manufacturing is required. It is utterly important not only to gain new knowledge, but also to convert it into a new product as soon as possible and to launch the product which competitors do not have, but consumers need, into the market. That is why scientists, designers and technologists work together in the company on solving scientific and technical tasks.

Competitive advantages of the TECHNOPARK:

• competences(especially,experienceinsupportinginnovationenterprisesandprojects);

• preferentialtaxtreatmentoftheresidents’innovationactivityinaccordancewithVoronezhregionlegislation;

• qualifiedpersonnel,availabletechnologicalcomplex;

• wideassortmentofservicesproposedtoresidents;

• continuousdevelopment;

• uniquenatureandcompetitivenessofproposedservices;

• closecooperationwithresidentsinimplementationofbusinessprojects;

• тесноесотрудничествосрезидентамивреализациибизнес-проектов.

The management company renders the following types of services to the TECHNOPARK residents:

1. Creation of advanced infrastructure:

- renting out production, office, representative and other premises in economically justified and mutually beneficial conditions;

- provision of technical, technological, information and additional services;

- outsourcing and subcontracting.

2. Consulting services:

- identification and selection of potential market-efficient innovations and their further support along the innovation cycle till production of pilot samples and manufacturing application;

- business planning, project management, technical and technological audit;

- consultations on accounting, taxation and law;

- legal services, intellectual property protection;

- functional-cost analysis and reduction of expenditures for development and manufacturing;

- finding the methods to improve product competitiveness.

3. Assistance in obtaining financing for the projects:

- searching for sources of financing;

- consultations on how to prepare innovation applications and investments memorandums;

- pre-investment preparation for residents’ projects;

- consultations on preferential tax treatment of the TECHNOPARK residents;

- involvement of the TECHNOPARK residents into federal and regional programs.

4. Promotion of scientific and technical products:

- searching for potential customers;

- organization of seminars and conferences;

- assistance to residents participating in various exhibitions.

5. Establishment of partner relations:

- assistance in establishment of relations with authorities of all ranks;

- assistance in establishment of region-to-region and international relations;

- assistance in establishment of relations with high schools and scientific research institutions.

6. Organization and development of the system for staff training/retraining.

Currently there are 5 residents within the TECHNOPARK territory, more than 1000 workplaces have been established.

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DesignationThe slug catcher skid is designed for preliminary

removal of liquid drops and solids from gas and to receive peak liquid discharge from low elevation gas pipes.

ApplicationCan function as part of central processing

facilities, field compressors, hydrocarbon refineries and chemical plants.

Design and operationThe basic components of the slug catcher skid

are:- a slug catcher/separator;- a valve block.

There are service platforms and ladders with rails on the skid for repair and maintenance.

The slug catcher/separator comprises vertical cyclone scrubbers combined with a horizontal tank to receive liquids and with a system to remove solids.

A formation fluid is fed from inlet lines to the cyclone scrubbers where the gas-liquid mixture is swirled by vortex tube blades. Each scrubber includes a vortex tube with blades, a hopper to prevent liquid carry-over with a clean gas stream, and anti-rotation plates to stop liquid rotation.

Driven by a centrifugal force the liquid drops and solids are forwarded to cyclone walls to form a liquid film which moves to the lower part of the cyclone scrubber.

The gas clean from liquids and solids leaves the cyclones via a central duct connected to gas outlet nozzles.

The liquid phase goes to the horizontal tank with continuous and periodical solid removal system.

Basic components of the skid are made of a low alloy steel 09Г2С as per GOST 19281-89.

The outer surface has anticorrosion coating.

The skid has an external heating and thermal insulation.

The equipment is mounted on three saddles, the two of which are free, and the one is fixed.

Slug Catcher / Separator Skid

Slug volume, m3 5-60

Efficiency of gas separation when slugs are received, % weight 90-80

Efficiency of gas separation from liquid drops, % weight 98

Efficiency of gas separation from solids, % weightRemoval of all particles:25 microns and more - 100size 25 microns - 85

Operation conditions

KOSMOS-NEFT-GAS Service Company

The KOSMOS-NEFT-GAS Service Company was founded on 14.01.2016 as a subsidiary undertaking for the Financial & Industrial Company KOSMOS-NEFT-GAS. At present the Service Company accomplishes the entire complex of pre-commissioning and commissioning works to start-up and maintain diverse process equipment at off-shore and ground based hydrocarbon production, processing and transportation facilities, i.e.:

1. On-site equipment installation

2. Installation supervision

3. Commissioning

4. Maintenance and warranty servicing

5. Post-warranty servicing

6. Intermediate and overhaul repairs

7. Performance tuning and testing

8. Training of operator’s staffs

Our personnel is highly qualified for all concerning industrial activities.

The abandoned experience, skilled labour and continuous professional improvement contribute into the highest work quality.

Durable trust-based relations with customers are the key for long-term sustainable success in times of relentless market competition. Quality servicing is the main competitive advantage in many industries and it is a contemporary standard to evaluate a service provider.

KO

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Slug

Cat

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Gas

Sep

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or S

kid

Gas Separator Skid With “Gas-Gas” Plate Type Heat Exchangers

Designation

The skid is designed to remove liquids and solids from a natural gas.

Application

It can operate as part of a central processing facility at gas condensate fields as well as at oil and gas production and refinery facilities.

Design and operation. The gas separator skid with «gas-gas» plate type heat exchangers consists of:• a high efficiency intermediate

gas separator fully complete with piping, valves and instruments

• a high efficiency lowtemperature gas separator fully complete with piping, valves and instruments

• a frame with two high efficiency “gas-gas” plate heatexchangers fully complete with piping, valves and instruments

• valveblocks

• processpipingforinternalandexternalconnections

• constructionsteel(railing,frames,pipingsupports,enclosures,racks, shelves).

The skid is mounted on metal frames with railing. Each frame within the entire skid maintains the strength required during transportation, final assembly and field operation.

Operation conditions

From -60°C to +50°C.

Advantages

- Effective operation over a wide pressure range

- Small footprint owing to skid mounted high performance equipment

- Reduced metal consumption, mounting and commissioning works in the field.

Technical characteristics

Description Measurement units Value

Intermediate gas separatorGas outputDesign pressureDesign temperatureMass concentration of liquid allowed in stripped gasMass concentration of solids allowed in stripped gasOverall loss of pressure in gas separator

MM n.m3/dayMPa°Cg/n.m3

g/n.m3

MPa

12 max.20 max.-60 to +700.0150.0050.019

Low temperature gas separatorGas outputDesign pressureDesign temperatureMass concentration of liquid allowed in stripped gasMass concentration of solids allowed in stripped gasOverall loss of pressure in gas separator

MM n.m3/dayMPa°Cg/n.m3

g/n.m3

MPa

12 max.10 max.-60 to +700.0050.0050.019

Plate heat exchangerHeat exchange surfaceDesign pressureInlet-outlet pressure drop

Design temperature

m2

MPaMPa

°C

27020 max.plate side – 0.005shell side – 0.005-60 to +100

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Gas Separators

Composition of 20 C-1

Item Designation Description Quantity

1 103.5746.00.000 Intermediate gas separator 20 C-1

1

2 Caged platforms at elevation of +1,000 m; +2,200 m; +4,500 m; +5,800 m; +6,850 m

Designation of gas separator 20C-1

The gas separator 20C-1 is constituent of a unit, designed to separate liquid drops and solids from unstripped gas downstream of heat exchangers.

Composition of 20C-1 is shown in the figure.

Application

20C-1 operates from -60°C to +50°C

Designation of gas separator 20C-2

The gas separator 20C-2 is constituent of a unit, designed to remove hydrocarbon condensate from a gas-liquid mixture downstream of a turbine expander.

Composition of 20C-2 structure is shown in the figure.

Application

20C-2 operates from -60°C to +50°C

Composition of 20 C-2

Item Designation Description Quantity

1 103.5747.00.000 Low temperature gas separator 20C-2 V=12 m3

1

2 Caged platforms at elevation of +1,000 m; +2,200 m; +4,500 m; +5,800 m; +6,850 m

Type 20 C-2

Type 20 C-1

Gas

Sep

arat

ors Design

The casing consists of all welded two el-liptical bottoms and a shell.

The casing has a cylindrical support with holes for foundation bolts.

The device is equipped with an inlet unit with a vortex breaker and three separation sections:

• ameshagglomeratortotrapcatchingliq-uid drops;

• a block of knockout cyclones to trap amist and liquid drops;

• coalescingfilterstotrapliquidsprays.

Along the body height there are nozzles for product inlet/outlet and to connect control and measurement devices.

Process parameters can be measured lo-cally of remotely.

Service platforms and ladders with guard rails are attached to the casing at different elevations for maintenance. There are a man way and two access doors. The access doors are equipped with sealed covers. The lower el-liptical bottom has electric heating at a height of 500mm.

Gas capacity, st. m3/h at to=20°C – 490697 (max).

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Fuel Gas Treatment Skid

Designation

The gas treatment skid is de-signed to reduce and maintain the preset pressure of a dried natural gas, treated in accordance with the Russian State Standard GOST 5542 for further usage as:

• a fuel at boiler houses, gas anddiesel power plants, antifreeze and gas condensate heaters, flare units and their pilot burners

• air displacement from conden-sate lines.

Application

To operate at central processing facilities, compressor stations, gas re-fineries etc.

Climatic modification – as per GOST 15150.

Operation – year round, daily con-tinuous.

Design

The skid consists of the follow-ing equipment with connecting piping, control valves and instruments:

• “hot antifreeze – gas” heat ex-changer to heat up a dried natural gas before pressure reducing

• strainers to remove solids up-stream a pressure reduction unit

• process piping for internal andexternal connections

• steel structures comprising aframe, piping supports, enclo-sures, consoles and mounting racks.

Auxiliary piping for inert gas blow-down and steaming are equipped with a quick connection.

The base frame ensures proper integrity during transportation and installation.

Fuel

Gas

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kid


Parameter Value

Operating temperature, °C indoors +15

absolute minimum -56

average of coldest five-day period -46

Mediumcategory and group of explosion hazard

category and group of explosion hazard as perGOST R 51330.5, GOST R 51330.11

IIA-T1

class of hazard as per GOST 12.1.007 4

Power supply electric reliability as per STO Gazprom 2-6.2-052-2006 III

Type of premise by fire hazard rating as per SP 12.13130 A

of pipe connection flanged

Service life, years 30

Design and Operation

Natural gas, dehydrated to gain parameters required by the Gazprom quality standard STO 089-2010, is fed to a bulk gas me-tering unit. Downstream the metering unit the gas enters a heat exchanger to be heated by a hot anti-freezing agent.

The heated gas goes from the heat exchanger to a reduction unit (that comprises working and stand-by lines with pressure regulators, filters and safety valves) and further on to pressure release stacks.

The dry gas is supplied to consumers via metering units with pressure regulators.

Gas output, n.m3/h at t°=20°C – 9501 (max.)

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Air Compressor Skid

Designation

The air compressor skid is designed to prepare compressed air to feed pneumatic devices (instruments) and for process needs.

Application

The equipment can be used at central processing facilities, pipeline compressor sta-tions, central production facilities, oil pumping stations, oil/gas refineries and at chemical en-terprises.

Application

The skid is operated at ambient tempera-ture from -60 to +35°C.

Transportation temperature is -20°C.

Climatic modification – ХЛ 1 as per GOST 15150-69.

Wind velocity area as per SP 20.13330.2011 (SNIP 2.01.07-85).

Fire danger rating as per SP 12.13130.2009.

The equipment is used in a fire dangerous area (as per PUE) – П 1.

Operation mode – year-round and peri-odical within 24 hours.

Composition

The supply scope includes:

• acompressorunit;

• aircleaninganddryingunitwithcontrols,includingagreasecatcher,aircollectors,complexofdryerswithpreliminaryandfinefilters and condensate collecting tanks.

The skid is also provided with:

• anairheating,ventilationandconditioningsystem;

• afirealarmsystem,annunciationandevacuationcontrolsystems.

Characteristics

Description Value

Pressure, MPa opearting, max 1,0 MPa

Dew point, °C minus 60

Permissible mass concentration of mechanical impurities in compressed air Particle size 0,01micron – 0,001%

Permissible mass concentration of oil in compressed air, mg/m3 0,003

Permissible mass concentration of oil in condensate, mg/l less than 15

Capacity by air 600

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Skid

HP Membrane Type Nitrogen System

Designation

Recovery of 95 - 99% purity controlled nitrogen from atmospheric air at a pressure of 50 ata.

Operation

Nitrogen is recovered by membrane separation of air. The membranes are vibration and shock resistant, chemically inert to oils and insensitive to moisture.

Membrane system advantages:

- easy to operate

- containerized modular design

- supplied ready to operate

- noiseless operation

- automated unattended technology

- high efficiency

- low prime cost of the produced nitrogen

- functioning temperature from -40 to +60 °C

- service life of the membrane unit – 15-20 years

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Designation

The well automation skids (hereinafter referred to as the skids) are designed for gas/gas-condensate wells located in the areas of the Extreme North, with minimum required scope of construction and assembly works applicable to tie-in and unification of gas well piping and environmental protection.

The skid complete with a wellhead control panel performs the following main functions:

• transportationofproducedgasfromawelltoacollectingheaderofawellcluster;

• measurementofpressure,temperatureandflowrateoftheproducedgas;

• automaticmeasurementofparameters(pressure,temperature,density,velocity,waterhold-up)ofgas-liquidflowwithoutitsseparation into component fractions;

• measurementandcontrolofhydrateinhibitorflowsuppliedtothewell;

• transportationofproducedgastoahorizontalflareofawellcluster;

• continuousfeedofworkingagentundertherequiredpressureintohydraulicdrives(incasethehydraulicdrivesareused)ofamaster valve, a wing valve, a subsurface safety valve, a flowline isolation valve to keep them in open position before the closing command is sent from the panel control board or from the system of automatic well cluster control or until the protection system actuates. Supply of the working agent (in case the hydraulic drives are used) to open a flare line valve by the command from the control board or from the system of automatic well cluster control with additional action confirmation;

• remotecontrol(openandclose)ofawingvalve,aflowlineisolationvalveandaflarelinevalvefromthesystemofautomaticwell cluster control;

Well Automation Skids

Wel

l Aut

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Skid

s • control(openandclose)ofawingvalve,amastervalve,asubsurfacesafetyvalve,aflowlineisolationvalveandaflarelinevalvefrom the panel control board;

• emergencyclosingofawingvalve,amastervalve,asubsurfacesafetyvalve,aflowlineisolationvalvebythesignalproducedby pushing the emergency button located on the panel control board, by “Fire” signal or in case of pressure increase/decrease in the well working pipeline, adhering to the required process sequence, namely: first the wing valve closes, then the flowline isolation valve and the head valve, and then the subsurface safety valve. The flare line valve opens when receiving an additional confirmation. The sequence is secured by a programmable controller of the system of automatic well cluster control;

• remoteemergencyclosingofawingvalve,aflowlineisolationvalve,amastervalve,asubsurfacesafetyvalveandopeningofaflare line valve by signal from the system of automatic well cluster control. In case the emergency protection initiates the shut-down process, the well may only be opened and put in service from the control panel;

• control(openandclose)ofanangularchokevalve(ACV)fromthecontrolpaneltoprovidetheflowratepresetinthesystemofautomatic well cluster control;

• openingofsurfacevalves,asubsurfacesafetyvalve,aflowlineisolationvalveinthefollowingsequence:asubsurfacesafetyvalve, a master valve, a flowline isolation valve, a wing valve, and securing this sequence by appropriate interlocks;

• acknowledgementandtransferofpositionsignals(open,close)fromhydraulicallydrivenvalvesandasubsurfacesafetyvalvein the system of automatic well cluster control;

• collectionandprocessingofsignalsfromsensorsinstalledonthewellandintheskidwithsubsequentdatatransferalongadigital channel to the system of automatic well cluster control;

• generationandtransferofclosingcausesignalsforsurfacevalves,anangularchokevalveandasubsurfacesafetyvalve,intothe system of automatic well cluster control such as:

• exceedingpressuresetpointlimitsinagastransportationpipeline;

• fireatawellhead;

• generationandtransferofemergencyandwarningsignalsintothesystemofautomaticwellclustercontrol,suchas:

• lowoillevelinthehydraulictankofthepanel;

• lowpressureinthehydro-pneumaticaccumulatorsofthepanel;

• measurement of pressure in thewell buffer, annular pressure, intercasingpressure andgas temperature in the string andtransfer of these data into the system of automatic well cluster control.

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Well automation skid МОС2/1-11with standalone power supply for electrically driven X-mas tree valves

Designation

МОС2/1-11 well automation skid is designed for:

• transportation of producedgas from a well to a collecting header of a well cluster;

• measurement of flow rate andtemperature of gas fed from a well (signals from a flow meas-uring unit are integrated into the system of automatic well cluster control);

• signaltransferfromapressuresensor installed in a well or system of automatic well clus-ter control;

• measurement and control ofhydrate inhibitor flow supplied to the well (signals from instru-ments are integrated into the system of automatic well cluster control);

• controlofelectricallydrivenX-mas treevalvesandahydrau-lic subsurface safety valve of normally closed and non-return type;

• flowadjustmentofgasfedfromawelltoawellcluster;

• switchingofgasstreamfromawelltoahorizontalflareunit.

The skid is energized from a standalone power source. Therefore it is independent from exterior networks such as power transmission lines that reduces costs for well cluster construction. Standalone power sources operate in several stages: power recov-ery, conservation and output. The power can be recovered in vari-ous ways to achieve maximum reliability and safety, for instance, by means of a stirling engine and diesel generators. Conservation is accomplished with accumulator batteries for optimum and efficient power consumption during the entire service life of the skid.

.


Value Unit Description

Max operating pressure- of gas line- methanol line

MPa10,1411,14

Max design pressure- of gas line- methanol line

MPa11,4713,5

Max test pressure- of gas line- methanol line

MPa17,517,5

Operating pressure in a hydraulic actuator of a subsurface safety valve

MPa 20...40

Operating medium:

- of gas line

- methanol line

- of a hydraulic line

- Natural containing upto 0,6% of CO

- Methanol as per Russian GOST 2222-95

- Polymethylsiloxane compound fluid type «PMS-20-Yugra» as per specification TU 2229-002-94483128-2007

Power supply 380V 50 Hz, five wire, four wire

Max installed power of electric equipment KW 2

Climatic modification УХЛ1 ГОСТ15150-69

Max overall dimensions- length- width- height

mm 1050030002280

Max weight kg 2300

Wel

l Aut

omat

ion

Skid

s

22 23

Designation

The manifolds and valve blocks, PN 4 … 70 MPa, DN 10 … 350 mm, are designed for single or multiple gas wells and perform the functions* as follows:

• transportationofproducedgasfromawelltoaclustergathering header

• controlofproducedgasflow

• productionratemetering

• gasstreamswitchingfromawelltoaflare

• gasstreaminhibiting

• automaticgasstreamblockageinfireemergency

• automaticgasstreamblockageincasepipelinepres-sure exceeding limited values

• gasstreamblockagefromaremotecontrolpanel

• localgasstreamblockage

• pressureandtemperaturemeasurement

• transferofstreamcontrolinstrumentdatatoanupperlevel control system.

*Performance list may be customized

The valve block package for single or multiple wells is a complete pipework system including welded pipe segments and valves mounted on unified skids.

The valve blocks can be supplied complete with a free ventilated shelter which can be equipped with lifting mechanisms.

To avoid harsh environment influence the valves and the I&C instruments are kept inside weatherproof enclosures.

Usage of the valve skids can optimize well construction works, reduce engineering time, hasten commissioning stage and harmonize different pipework packages.

Pipeline Manifolds and Valve Blocks

Wel

l aut

omat

ion

skid

for

conc

entr

ic tu

bing

wel

ls

Well automation skid МОС2/1-04 for concentric tubing wells

Designation

МОС2/1-04 well automation skid (for concentric tubing wells) is designed for automated monitoring and control of gas wells equipped with concentric tubing.

The skid is applicable at depleted gas fields (self-killed wells loaded with water and sand plugs) including off-grid applications.

Design and operation

The skid is arranged as a sheltered block of process piping and associated equipment. The shelter itself consists of a ventilated part with an operator’s panel and a heated cabinet with basic equipment. Some equipment is fixed on external walls outside the shelter. The cabinet and the local control console are accessed via doors in the cabinet. The skid controls a production rate of one gas well equipped with a concentric tubing.

The basic function of the skid is to maintain gas production rate in a central production string and in a combined flow string at a level sufficient for continuous trouble-free well operation and to avert self-killing due to internal water and sand plugs.

Application:

The skid can operate in open air in the conditions suitable to meet category «УХЛ» as per Russian GOST 15150, ambient temperature from -60°C to +35°C. Explosion hazard rating 2 as per GOST 30852.9. Explosive mixture category IIА as per GOST 30852.11, explosive mixture group Т1 as per GOST 30852.5.

GOST 30852.9. Explosive mixture category IIА as per GOST 30852.11, explosive mixture group Т1 as per GOST 30852.5.


Description Unit Value

Operating medium untreated natural gas

Pressure of operating medium MPa 0,8 ... 2,5

Temperature of operating medium °С plus 1 … plus 12

Gas production in a central production string st.m3/hour 200 … 1600

Gas production rate st.m3/hour 0 … 3700

Gas production in a combined flow string st.m3/hour 200...5300

Ambient temperature °С minus 60 … plus 35

Supply voltage V 24 DC

Max power consumption W 343

Max overall dimensions LxWxH Mm 8790х2845х6390

Max weight ton 8,5

24 25

Con

trol

Sys

tem

s Control systems are designed to control:

a subsurface safety valve, control and shut-off equipment of oil and gas wells, oil and gas condensate pipelines, underground gas storages at any climatic zones.

Design of control systems depending on the number of equipment to be controlled and a climatic modification:

• singlewellcontrolsystems;

• systemstocontroltwoorthreewellslocatedwithin100mawayfromthesystem;

• systemstocontrolacomplexofwellheadsaticeresistantplatforms–upto30wells;

• cabinetstocontrolactuatorsofisolationequipment;

• panelstocontrolactuatorsofisolationequipment.

Design of control systems depending on the type of actuators to be controlled:

• systems,cabinetsandpanelstocontrolhydraulicactuatorsofisolationvalvesand(or)gatevalves;

• systems,cabinetsandpanelstocontrolhydraulicactuatorsofsubsurfacesafetyvalvesand(or)pneumaticactuatorsofgatevalves;

• systems,cabinetsandpanels tocontrolhydraulicactuatorsofsubsurfacesafetyvalvesand (or)electricactuatorsofgatevalves.

The control logic can be configured specifically for a separate field using:

• differentarrangementsequenceoflogicalhydraulicorpneumaticvalves;

• softwarecontrolofsolenoidvalves.

Control systems can be mounted:

• onaframestructureforindoorlocation,e.g.atoff-shoreplatforms;

• inacabinetmadeofstainlessorpaintedcarbonsteelwithorwithoutheating;

• onanopenconsole.

Functionality of control systems for electrified wells:

• manualcontrolofactuatorsofisolationvalvesandcontrolequipmentfromthelocalconsoleofasystem;

• automaticclosingofactuatorsofisolationvalvesandgatevalvesinemergencysituationsi.e.firepiperupture,pressurerisingin a product treatment system in response to a hydraulic, pneumatic or electric signal;

• remotecontrolofactuatorsofisolationvalvesandgatevalvesinresponsetoanupperlevelcommand;

• remotecontrolofaproductionrate;

• monitoringofparametersofawellheadequipmentandacontrolsystemwithdatatransferintothesystemofautomaticwellcluster control;

• remotecontrolofthesystempumps;

• autonomous control ofwellhead equipment and transfer ofwell pipingdata (while installing a controller) to the systemofautomatic well cluster control.

Functionality of self-contained control systems for non-electrified wells:

• manualcontrolofactuatorsofisolationvalvesandcontrolequipmentfromthelocalconsoleofasystem;

• automaticclosingofactuatorsofisolationvalvesandgatevalvesinemergencysituationsi.e.firepiperupture,pressureriseina product treatment system in response to a hydraulic or pneumatic signal.

These systems are equipped with manual or hydropneumatic pumps. Hydropneumatic accumulators or gas cylinders are used for a working medium back-up.

Control Systems

Abbreviations: SSSV – subsurface safety valve, WV – wing valve, MV – master valve, FV – flowline valve, UMV – upper master valve, ACV – angular choke valve

Basic characteristics

System code

Number of controlled wells

Control of actuators Type of pump drive

Emergency shut-down

Fire signal from

Emergency pipeline pressure from

1 2 3

ove

r 3

SS

SV

WV

MV

FV

UM

V

AC

V

ga

te v

alv

e

ma

nu

al

ele

ctri

c

pn

eu

ma

tic

fusi

ble

plu

g

tra

nsm

itte

r

LP p

ilots

HP

pilo

ts

Co

mb

ine

d L

P-H

P

pilo

ts

tra

nsm

itte

r

SUFA1.001 ˅ ˅ ˅ ˅ ˅

SUFA2.001 ˅ ˅ ˅ ˅ ˅ ˅

SUFA2.002 ˅ ˅ ˅ ˅ ˅ ˅

SUFA2.003 ˅ ˅ ˅ ˅ ˅ ˅ ˅

SUFA3EGP ˅ ˅ ˅ ˅ ˅ ˅ ˅

SUFA3.002 ˅ ˅ ˅ ˅ ˅ ˅ ˅ ˅

SUFA3.003 ˅ ˅ ˅ ˅ ˅ ˅ ˅ ˅

SUFA4.001 ˅ ˅ ˅ ˅ ˅ ˅ ˅

SUFA6.004 ˅ ˅ ˅ ˅ ˅ ˅

SUFA8.001 ˅ ˅ ˅ ˅ ˅ ˅ ˅ ˅ ˅ ˅

SUFA12 ˅ ˅ ˅ ˅ ˅ ˅ ˅ ˅

SUFA12/2 ˅ ˅ ˅ ˅ ˅ ˅ ˅

SUFA12/6 ˅ ˅ ˅ ˅ ˅ ˅ ˅ ˅

SUFA12/9 ˅ ˅ ˅ ˅ ˅ ˅

SUFA12/15 ˅ ˅ ˅ ˅ ˅ ˅ ˅ ˅

SUFA77.001 ˅ ˅ ˅ ˅ ˅ ˅ ˅

SUFA77.002 ˅ ˅ ˅ ˅ ˅ ˅ ˅

SFK60 ˅ ˅ ˅ ˅ ˅ ˅ ˅

SHAZK ˅ ˅

SHAZK1 ˅ ˅

SHAZK2 ˅ ˅ ˅ ˅ ˅

SHAZK3,SHAZK4 ˅ ˅ ˅ ˅ ˅

26 27

Con

trol

Sys

tem

s

Control Systems

SUFA 12/15

Panel to control hydraulic actuators of subsurface safety valves, master valves, wing valves, flowline isolation valves and angular choke valves at three gas condensate wells.

Basic functions

• manualopen/closecontroloftheactuators

• remoteclosingofseparatewells

• remoteclosing/openingofawingandflowlinevalves

• remotecontroloftheproductionrate

• automaticwellshut-downinemergency

• transferoftheemergencywellshutdowncausedatatothe system of automatic well cluster control (discrete signal)

SFK60

Panel to control a hydraulic actuator of a subsurface safety valve (SSSV), pneumatic actuators of a master valve (MV) and a wing valve (WV) of a well with gas condensate containing upto 28% hydrogen sulfate.

Basic functions

• WV,MV,SSSVopening/closingfromacontrolconsoleofthepanel

• remotewellshut-down(WV,MR,SSSVclosing)

• remoteWVclosing

• automatic WV, MV, SSSV closing in emergency, such as fire, flowlinepressure fall upstream the flow regulator

• automaticWVclosingincaseofflowlinepressurefall/risedownstreamtheflow regulator, panel power loss

• transferoftheemergencywellshutdownorWVclosingcausedatatothesystem of automatic well cluster control (discrete signal).

SUFA3EGP

PLC panel to control a hydraulic actuator of a subsurface safety valve (SSSV), pneumatic actuators of a master valve (MV) and a wing valve (WV) of a well with gas condensate containing upto 28% hydrogen sulfate.

The controller provides:

• controlofSSSV,MV,WVactuators

• formattingandlocaldisplayingofawellandpanelequipmentstatus

• receivingcontrolsignalsfromanautomatedprocesscontrolsystem

• data exchange with an automated process control system via RS485interface

SUFA4.001

Panel to control hydraulic actuators of a subsurface safety valve (SSSV) and a wing valve (WV) of two gas condensate wells.

Basic functions

• WV,SSSVopening/closingfromacontrolconsoleofthepanel

• remoteWV,SSSVclosing

• automaticwellshut-downinemergency,suchasfire,flowlinepressurefall

• transferoffireandpressurealarmstothesystemofautomaticwellclustercontrol

• continuousdisplayofoperatingparametersi.e.pumpdischargepressure,SSSVandWV control pressure, temperature inside the cabinet etc.

To facilitate servicing and for a heat accumulation purpose the cabinet is divided to compartments and is equipped with a heat accumulator.

Panels to control a pneumatic actuator of a gate valve

Basic functions

• remoteactuatoropening/closing

• canbedesignedtoallowremoteclosingof the main valve actuator and automatic close-locking of a solenoid valve.

Built-in safety, control and isolation valves.

28 29

Сис

тем

ы у

прав

лени

я Panels to manually control a hydraulic actuator of a subsurface safety valve, a wing valve and a master valve

Basic functions

• opening/closingofvalveactuators

• automaticclosingofvalveactuatorsinemergencyi.e. fire, fall of piping pressure.

Panel to control hydraulic drives of a upper master valve (UMV), wing valve (WV) and a casing head valve (CHV)

Basic functions

• CHV,UMV,WVopening/closingfromacontrolconsoleofthepanel

• remoteCHV,UMV,WVclosingbyanupperlevelcommand

• automaticwellshut-downinemergencyi.e.fire,gaspressurefall/riseupstream the CHV

• transferofalarmsandwarningsignalstotheupperlevelcontrolroom(discrete signals).

SHAZKAutomated valve control panel for hydro-pneumatic actuators at

gas condensate pipelines

Basic functions

• valve opening/closing from a control console of the panel usingmanual overrides of solenoid valves;

• remotevalveclosingbyanupperlevelcommand;

• automaticvalveclosingfromLPpilotsinresponsetoapressurefallata gas condensate line.

SHAZK1 and SHAZK-M

Automated valve control panel for hydro-pneumatic actuators at gas condensate pipelines are composed of a controller, control and indication console, signal distribution and control unit, discrete control unit, dedicated software for autonomous and remote valve control based on a preset algorithm.

Basic functions

• valve opening/closing from a controlconsole of the panel by an electric command;

• remotevalveopening/closingbyanupperlevelcommand;

• automatic valveclosing in caseofgaspressure fall/riseup to setvalues of pressure transducer readings;

• valve opening/closing in case of power shutdown using manualoverrides of solenoid valves at opening/closing lines.

Panel to control a pneumatic actuator of an inlet manifold valve

Basic functions

• valveopening/closingfromacontrolconsoleofthepanel

• remotevalveclosingbyanupperlevelcommand

HP/LP pilots are designed to automatically send control signals to a well control system as well as to drain a control liquid from the drives in case the field pipeline pressure exceeds the limited values.

The following options are available:

- combined low and high pressure design- low pressure design- high pressure design

The pilots can be normally open and normally closed.Working medium – liquid, gas.

Con

trol

Sys

tem

s

Control Systems

30 31

Con

trol

Sys

tem

s

Offshore control systems

The system is designed to control 11 wells of an offshore ice-resistant oil production platform:

• 8productionwells;

• 2water-injectionwells;

• 1gas-injectionwell.

After being upgraded with extra drawer modules the panel can control 18 wells i.e.:

• 13productionwells;

• 3water-injectionwells;

• 2gas-injectionwells.

The system is a skid with drawer modules installed in a separate compartment of a platform.

The system consists of the following components:

• hydraulic power unit in-cluding hydraulic power equipment, all necessary triggers and controls, a fusible loop line, a fire alarm and emergency shutdown module;

• 8drawermodulestocontrolproductionwells;

• 1drawermoduletocontrolagas-injectionwell;

• 2drawermodulestocontrolwater-injectionwells;

• electricequipment,softwareandhardwarecomplex.

Basic functions

1. The system controls every separate production, gas-injection, water-injection well of the platform in the following sequence:

• manual opening/closing of WV, MV, SSSV of production, gas-injection, water-injection wells from the local controlconsole;

• remoteopening/closingofWV,MV,SSSVofeveryseparatewellfromtheprocesscontrolsystemofaplatform(PCS).

2. The system can simultaneously control all production, gas-injection, water-injection wells of the platform, i.e.:

• manualcontrolofwellactuatorsfromthelocalcontrolconsole;

• remoteemergencyclosingofwellactuators;

• monitoringandtransmissionofparametersintothePCS;

• transmissionofwellstatedataandemergencyalarms.

32 33

Inhi

bito

r In

ject

ion

Uni

t

34 35

Designation

The unit is designed for automatic metering and distribution a hydrate formation inhibitor among injection points.

The unit performs the following main functions:

• automaticmaintainingofthepresetinhibitorflowateach channel

• remote monitoring and manual control of theinhibitor flow at each channel

• transferofeachchanneloperationparametersviaacommunication line

• warning about faulty operation of the constituentparts

Inhibitor Injection Unit


Parameter Measurement unit

Value

Type of the unit electric

Operating medium methanol, glycols and their mixtures

Operating medium pressure MPa 25

Operating medium temperature °C -60 to +40

Ambient temperature °C 5…42

Pipeline gas pressure MPa 6.5 … 9.2

Power voltage V 220, 380

Minimum pressure drop allowed MPa 0.5

Number of independent injection points Nos 6

Max. relative flow maintenance error % ±2

Type of electric equipment Ex-proof

Control communication interface (by a controller or a field computer)

RS-485


The scope of supply includes an inhibitor injection block and an installation kit.

The unit operates as follows:

The injection block control system energizes an electric drive motor in response to an operator’s command. The motor transfers its rotation via a reducing gear and a connection clutch to a stem to change a control valve opening extent.

The liquid in the pipeline goes through a flowmeter, the output signals of which are sent to the electronic control system to process them accordingly: to display, to archive, to generate commands for the drive motor and to transfer pressure, flow and other parameters of the inhibitor.

In case the flow regulator is under repair the inhibitor is forwarded through a by-pass line with a needle valve installed. The liquid flow rate is controlled depending on the flow meter readings when the needle valve opens/closes.

Operating conditions

The inhibitor supply unit can be operated at mild climate conditions type У1 as per GOST 15150-69, explosion hazardous zones class 2 as per GOST R 51330.9-99.

DesignationNumber of injection points

Flow rate, l/hWorking pressure, MPaTotal At a preset flow rate

КМЕВ611449.013.05.00.000 3 3 0,5…36 16

КМЕВ611449.013.15.00.000 3 3 15…300 16

КМЕВ611449.013.25.00.000 32 0,5…36

161 15…300

КМЕВ611449.15.05.00.000 6 6 1…130 15

КМЕВ611449.22.00.00.000 6 6 25…330 16

21 0,5…12

161 10…320

КМЕВ611449.21.00.00.000 1 1 0,5…10 40

Gas

Dis

trib

utio

n P

lant

s DesignationThe gas-distribution plants are designed for gas pressure

reduction (to maintain the required gas parameters – pressure and flow rate) from a field pipeline to industrial, agricultural facilities, settlements, located in areas with mild climate.

The plants perform the following main functions:

• safetyofoperationandstablemetrologicalcharacteristicsirrespective of any meteorological conditions;

• reductionofhighgaspressuredowntothespecifiedvalueand its automatic maintenance within a certain accuracy whenever input pressure or flow rate of gas change;

• automaticturningoffthegassupplyincaseofemergencyexceeding the specified gas pressure limits;

• incaseapressurecontrolandregistrationunitiscustomerrequired:

- time count since power dump;

- registration of pressure deviations;

- displaying current pressure values and the registered data on an interactive visualization panel via RS232 interface.

DesignThe internals are included into a cabinet of dismountable

design to allow the installation and repair works.

OperationThe gas distribution plants are arranged in a cabinet

mounted onto foundation bolts. The cabinet is equipped with a door, lightning protection and external gas line flanges to simplify the installation and repair works.

The pressure control and registration unit can be built in at the Customer’s request.

The plant has a single line of gas pressure reduction with a pressure controller with an inbuilt safety valve and a stop valve, and a controller bypassing line for gas transportation. A filter to clean the gas stream from mechanical impurities is installed upstream the controller. The controller automatically reduces the input pressure to an adjusted value and secures the required gas flow rate, maintains the specified output pressure irrespective of pressure and flow rate changes, turns off the gas supply in case of emergency exceeding the permissible output pressure limits.

The reduction and bypass lines are equipped with instrumentation to monitor gas pressure (pressure gauges, head flow meter) and a purging system.

Operating conditionsThe gas-distribution plants are designed to operate outdoors in seismically active areas up to 8 points with mild climate rated

as «У», location 1 as per GOST15150 at ambient temperature from -40±C to +45±C and relative humidity of (95±3) % at 35°C.

Gas Distribution Plants

Technical specification

Parameter, unit Unit ШРП100.3

ШРП100.6

ШРП100.12

Value

Output gas pressure mPa 0,3 0,6 1,2

Number of outputs 1

Output gas pressure, adjustment range kPa2...5

Pass through capacity m3/hr 100 105 64

Irregularity of control % ±10

Safety valve actuation pressure kPa 2,3...5,7

Stop valve actuation pressure:- high output pressure- low output pressure

kPa

2,5...6,21,5...3,8

Pipeline diameter:inputoutputpulse

mmmmmm

DN25DN32DN15

Inlet gas temperatureAmbient temperature

°С°С

from -10 to +60from -40 to +45

Cleaning system 40 micron strainer

Heating system -

Reduction system Type РНДК-32/10 – 1 piece

Type РНДК-32/6 – 1 piece

Type РНДК-32/3 – 1 piece

Control system pressure control and registration unit with interactive visualization panel via RS232 interface (at customer’s request)

Lightning protection included

Dimensions, without detachable and protruding elements (spark plugs, input/output nozzles, lightning protection, etc.):- length- width- height

mmmmmm

1,0608601,800

Weight kg 200

36 37

Gas

Deh

ydra

tion

Uni

ts

Designation

Gas dehydration units are designed to reach the intended parameters of natural gas (pressure, humidity, volume flow, amount of mechanical impurities) used as fuel, start-up and impulse gas.

The units provide the following main functions:

• gascleaningfrommechanicalimpurities;

• gasdehydrationtorequireddewpoint(from-30°Cto-70°C);

• automaticoperationcontrol;

• diagnosticsofactuatorconditionsandsendingemergencyandwarning signals in case of operation mode disturbance to the dispatcher’s or operator’s panel.

Produced gas dehydration units operate over the inlet pressure range from 2.4 to 7.5 MPa with efficiency from 50 to 750 st. m3/hr.

Arrangement

The gas dehydration units can be mounted on a steel plate (fig.1) or installed in a cabinet (fig. 2, 3), that provides convenient and safe assembly/repair works.

The units can be designed to operate in the areas with moderate climate II5 as per GOST 16350 in the conditions classified as У1 per GOST 15150 over ambient range from -36 to +46°C.

The unit is manufactured in compliance with the requirements of GOST 12.2.003, RD 39-22-617, “Safety codes for gas processing plants and facilities” PB 08-624, approved by Gosgortekhnadzor of Russia (State Mining and Engineering Inspection) in 2003, and of the “Instruction Concerning Safety in Work Relating to the Exploration and Development of Oil, Gas and Gas Condensate Deposits with a High Hydrogen Sulphide Content and other hazardous and aggressive substances” approved by Gosgortekhnadzor of Russia in 1994.

The internal electric equipment is made explosion-proof and designed for class 2 explosive areas as per GOST R 51330.9, IIA explosive mixture, T1 group according to GOST R 51330.0, and meets the requirements of “Electric device design codes”.

Gas Dehydration Units

Figure 1 Gas dehydration unit, panel mounted

Figure 2 Gas dehydration unit, in a cabinet


The unit comprises 2 adsorbers, pneumatic distributors, electric equipment cabinet, condensate tank, instrumentation panel, power terminal box, filters, ball valves, a dew point transducer, I&C instruments and pipelines.

The units operate as follows:

The incoming humid gas passes through a filter-moisture separator, where it is preliminary cleaned from condensed moisture and mechanical impurities, and arrives into the one of adsorbers through a pneumatic distribution system. The condensed moisture flows from the filter-moisture separator into a condensate tank by gravity, from where (as it accumulates) it is drained by the operator during a routine maintenance. Having passed through an adsorbent layer, the humid gas is dehydrated, separated into flows with different pressures and arrives into load lines via the outlets.

The adsorbers operate in turn: one in dehydration mode, the other one – in regeneration or stand-by mode. The humid adsorbent is regenerated by purging with dry gas. At the same time the electric heating element of the adsorber (the one where the adsorbent regeneration is in process) is started. The control system switches the adsorbers over from dehydration to regeneration, secures the regeneration process, monitors the outlet gas humidity and actuator serviceability, and sends data signals to the operator’s control board.

Figure 3 Gas dehydration unit in a cabinet

Figure 4 Gas dehydration unit at the KC gas booster plant in Bulgaria

38 39

Smok

eles

s Fla

re

Smokeless Flare

The flare provides smokeless burnout of gases and vapors from emer-gency discharge devices, routine blow-offs, regular and periodical dis-charge of gases and vapors at start-up, commissioning and process shut down. It is maintenance-free, and has low operating costs.

Standard composition

• flareshaftwithatip,laddersandrailedplatforms;

• automaticignitionsystem;

• fuelgastreatmentandreductionpipeline;

• flareseparator;

• draintankwithpumpstationforfluidremoval.

The equipment has a Certificate of Conformity issued by the RF State Standard GOST R certification system and the Permit of Use by the Federal Service for Environmental, Technological and Nuclear Supervision.

Flare shafts designs:

• self-bearing;

• guided;

• insideatowerpier;

• doubled;

• combined.

Flare shaft service life - 20 years.

Flare tips:

• jet-stream;

• withairsupply;

• withsteamsupply.

The tip is equipped with a kinetic speed gas seal, which eliminates am-bient air ingress into the flare shaft. The jet-stream tips provide smokeless burning without additional supply of steam or air into the burning area. The burning completeness is secured by the outflow speed of waste gases and their mixing with ambient oxygen right at tip section. The burning complete-ness is calculated by Tdsoft software, which analyzes thermodynamic and thermal properties of working substances that participate in processes of burning (heating ) and flowing.

Service life of flare tips is 5-10 years depending on operation intensity.

Operating flare at Ust’-Balyk Gas Processing Facility in Pyt-Yakh, Tyumen region. Flow rate - 180 tons/hour. Height - H = 71 m; DN = 1000 mm

Operating flare at central production facility at right-bank part of Priobskoe field of RN Yuganskneftegaz. Flow rate max = 90,000 st.m3/hour; min = 45,000 st.m3/hour. Flare shaft height H = 35 m. DN = 0.8 m, flame length = 42 m

60m tall combined shaft operating at the Verkhnechonsk oil/gas condensate field, oil treatment unit 1

Active flare unit at the Zapolyarnoye oil/gas condensate field, Gazprom dobycha Yamburg, DN=1420mm, height 60m

40 41

Flar

e Ig

niti

on C

ompl

exes

DesignationThe flare ignition complex is designed for gas-air mixture ignition and

constant maintaining of pilot burner flame at a flare shaft section.

ApplicationFor ignition and flame availability monitoring in flares at gas, gas

condensate and oil fields.

Composition and designation 1. Ignition device

Designed to produce and ignite the gas-air mixture in mixing chamber by HV spark plug unit and to send the burning mixture to pilot burners. The ignition device secures the flame ejection from the spark plugs to a height from 24 m - to 60 m.

2. Pilot device Comprises ignition and pilot burners and is designed to maintain

constant flame at the flare tip section. The flash pipe comprises a thermal electric transducer to monitor the flare flame availability.

3. Gas treatment unit Designed to treat and reduce the fuel gas for ignition and pilot

devices. The unit is designed for gas supply over the range from 3.2 to 3.5 MPa or from 0.4 to 0.6 MPa.

Note* - the pilot gas flow rate depends on its pressure when fed to the ignition and pilot burners.

The complex is delivered disassembled. The scope of supply comprises the following components:

- gas treatment unit;- flare control unit;- ignition device – in compliance with PB 03-591-03;- pilot device – in compliance with PB 03-591-03;- high voltage unit – one unit per two ignition devices.

Operating conditionsTemperature range - from -60°C to +50°C.

Flare Ignition Complexes


Designation Unit Type КЗФ.00-00.000 (КМЕВ.02)

Type КЗФ. 00-0.000- 01

Pilot gas flow rate st.m3/h 3.86…11.0*

Distance from spark plugs to flame ejection, max m 24.0 60.0

Fuel gas pressure when fed to treatment unit MPa 3.2…3.5/0.4…0.6 0.4…0.6

Fuel gas pressure when fed to ignition and pilot burners MPa 0.06…0.3*

Ignition system power supply:- voltage- frequency

VHz 220±10

50±1

Power consumption:- “stand-by”, max- “on”, max

W8100

Designation

The mobile vertical stack flares are designed to burn hydrocarbon gases and vapors in a smokeless manner without environment-polluting emissions in case erecting a stationary flare is not feasible.

The flare is designed as a motor trailer with a container with adjustable supports to fix the container frame position on the working site. The container internal equipment are: a lower stack section, a unit of fuel gas treatment c/w a propane unit, a device for air injection into the burning zone and a diesel generator for the flare. The remaining stack sections and a tip with the ignition system and instruments are the pull-out modules kept on the supports inside the container. The modules are connected to the lower stack section in horizontal position. The flare control instruments are installed in an isolated compartment of the container (I&C compartment).

To change the stack from the transport position into the working (vertical) position and backwards, the flare is equipped with the lifting and lowering appliances. When in the working position the stack is braced with guy lines to compensate for wind loads.

The discharged gas is supplied into the stack via the adapter which compensates for any possible misalignment of the flare inlet nozzle and the product discharge line.

The flare is ignited by the pilot burners. The pilot burners are ignited by the electric spark system automatically or manually. For automatic ignition the tip is equipped with the means to control flame availability at the pilot burners.

Parameters of the specific product design depend on customer’s preferences and are also based on the gas burning process calculations.

Mobile Vertical Stack Flare

42 43

Bur

ners

and

Fla

res Designation

The horizontal burners are designed to burn formation mixture at wells of gas and gas-condensate fields along with thermal dewatering of liquid phase, containing formation waters, condensate, corrosion inhibitor, remnants of drilling mud, flush liquid, as well as formation mixtures with high hydrogen sulfide content (up to 33 % volume).

Application

The burners operate in open air in mild macroclimatic conditions at the following ambient parameters:

- temperature from -60°C to +70°C;

- relative humidity up to 90 %;

- atmospheric fallout such as rain, dew and fog;

- height above sea level up to 1000 m;

- seismically active areas up to 9 points;

Any climatic modification as per GOST 15150.

Design

Main burner can be different design:

- with Coanda effect;

- with premixing;

- with stream separation.

Composition


- a burner unit, consisting of:

- a main burner;

- pilot burners;

- frame;

- a diaphragm gauge of critical flow (for the main burners with premixing);

- a fuel gas preparation unit;

- a control unit, consisting of:

- a solenoid valve control in manual and automatic mode;

- a high voltage unit control in manual and automatic mode;

- a process light indication;

- an ignition system, consisting of “running fire” ignition device and an electrospark on the pilot burner;

- a flame control system is provided with:

- a thermal couple;

- an ionizing probe;

- an optical flame sensor.

Horizontal burners for well blowing products

Burner with Coanda effect

Burner with flow separation


Parameter Unit Value

Formation fluid flow n.m3/h 550 to 58000

Formation fluid pressure MPa 0.6 to 1.2

Fluid gas for pilot and ignition burner as per GOST 5542-87

Max. fuel gas flow for pilot burner n.m3/day 10

Fuel gas pressure for pilot burner MPa 0.2 to 0.3


VHz

220±10*50±1

*At a customer’s request the ignition system can be powered from 24V autonomous supply source.

The systems can be redundant.

Burners are equipped with light and sound alarms to trigger in case of:

- delay in pilot burner ignition

- loss of pilot fire

- fuel gas pressure drop.

The treatment unit (if there is no treated fuel gas) can be equipped with a block of propane/methane cylinders.

Burner with flow separation

44 45

Hor

izon

tal c

ombi

ned

burn

ers

Horizontal combined burners

Designation

The horizontal combined burner is de-signed to burn:

- formation mixture of the wells to-gether with a thermal dehydration of a blowdown gas liquid discharge;

- waste gases from control valves.

Application

The burner operates in open air in mild macroclimatic conditions at the following ambient parameters:

- temperature from -60°C to +70°C;

- relative humidity up to 90 %;

- atmospheric fallout such as rain, dew and fog;

- height above sea level up to 1000 m;

- seismically active areas up to 9 points;

Any climatic modification as per GOST 15150.

Design

The unit consists of a burner with a velocity seal and a flow swirl to burn waste gases from control valves, as well as a burn-er with flow separation for formation mixture burning.

Composition


1. A burner unit consisting of:

- burners with a velocity seal and flow swirl;

- burners with flow separation;

- a pilot burner;

- a housing.

2. A fuel gas preparation unit;

3. A control unit consisting of:

- a high voltage unit control in manu-al and automatic mode;

- a process light indication;

4. An ignition system consisting of the high voltage unit, pilot burner high voltage electrode and connection wires.

– Horizontal combined burner type 500C

Horizontal combined burner type 500-21C

Characteristics of 500С

DescriptionValue

Formation mixture Waste gas Fuel gas

Flow rate, st.m3/h:- minimum- maximum

180023000

23000185000

1,55

Inlet pressure, MPa:- minimum- maximum- nominal

0,16,36,3

0,14,04,0

0,31616

Pilot burner inlet pressure, MPa:- minimum- maximum

--

--

0,050,2

Site seismicity (OCP-97), points 6

Weight, kg, not more 1800

Flame availability at the pilot burner is controlled by the ionization probe.

The burners are equipped with emergency light and sound alarm system to trigger at:

- flame ignition delay;

- pilot burner flame-out;

- fuel gas pressure reduction.

In case the fuel gas is not processed the preparation unit can be equipped with propane/methane cylinders.

Characteristics of 500-21С

DescriptionValue

HP gas LP gas Fuel gas

Flow rate, st.m3/h:- minimum- maximum

3854760

4560

1,55

Maximum inlet pressure, MPa: 0,6 0,105 16

Pilot burner inlet pressure, MPa:- minimum- maximum

--

--

0,050,2

Site seismicity (OCP-97), points 6

Weight, kg, not more 1000

46 47

Hor

izon

tal b

urne

rs fo

r ga

ther

ing

line

blo

win

g ga

s

Horizontal burners for gathering line blowing gas

DesignationThe horizontal burners are designed for

burning waste gas from gathering lines at central processing facilities.

ApplicationThe burner operates in open air in mild

macroclimatic conditions at the following ambient parameters:

- temperature from -60°C to +70°C;- relative humidity up to 90 %;- atmospheric fallout such as rain, dew

and fog;- height above sea level up to 1000 m;- seismically active areas up to 9 points;Any climatic modification as per GOST

15150.

DesignThe unit consists of a burner with a velocity

seal and a flow swirl.

CompositionThe supply scope includes:- a burner unit consisting of:- a main burner;- a pilot burner;- a frame;- a fuel gas preparation unit;- a control unit consisting of:- a solenoid valve control in manual and automatic mode;- a high voltage unit control in manual and automatic mode;- a process light indication;- an ignition system, consisting of “running fire” ignition device and an electrospark on the pilot burner;- a flame control system is provided with:- a thermal couple;- an ionizing probe;- an optical flame sensor.The systems can be redundant.Burners are equipped with light and sound alarms to trigger in case of:- delay in pilot burner ignition- loss of pilot fire - fuel gas pressure drop.At a customer’s request an additional stack can be installed in the frame to burn from relief valves.



Formation fluid flow st.m3/h from 600 up to 20800

Formation fluid pressure MPa from 1,4 up to 17

Fluid gas for pilot and ignition burner as per GOST5542-87

Max. fuel gas flow for pilot burner st.m3/d 10

Inlet fuel gas pressure MPa from 0,25 up to 0,3


VHz

220±10* 50±1

*At a customer’s request the ignition system can be powered from 24V autonomous supply source

Gathering line burner

Horizontal burners to burn process drains at oil, gas and gas condensate fields

DesignationHorizontal burners are designed for thermal

neutralization of process drains at oil, gas and gas condensate fields.

ApplicationThe burners can operate in open air mild

macroclimatic conditions at the following ambient parameters:

- temperature from -60°C to +70°C;- relative humidity up to 90 %;- atmospheric fallout such as rain, dew and

fog;- height above sea level up to 1000 m;- seismically active areas up to 9 points;Any climatic modification as per GOST 15150.

DesignGas intended to burn process drains gets split

into two streams. One of the streams is forwarded to a spray gas header and the second stream to the main burner header. Each line contains a control valve and a gauge for pressure control. At the outlet from the main burner header the fuel gas is ignited by a pilot burner. At the outlet from the spray header the fuel gas ejects ambient air, sprays process drains and gets mixed with it. The design provides for specific highly efficient nozzles to spray process drains. The mixture of process drains, fuel gas and air catches fire from the main burners.

CompositionThe supply scope includes:- a burner unit consisting of:- a process drain nozzle;- a spray header;- main burners;- a pilot burner;- a valve block;-acontrolunitconsistingofз:- a solenoid valve control in manual and automatic mode;- a high voltage unit control in manual and automatic mode;- a process light indication;- an ignition system, consisting of “running fire” ignition device;- a flame control system is provided with: - a thermal couple;- an ionizing probe;- an optical flame sensor.

The systems can be redundant.Burners are equipped with light and sound alarms to trigger in case of:- delay in pilot burner ignition- loss of pilot fire - fuel gas pressure drop.

Process drain thermal neutralization burner



Pressure of process drains МПа(кгс/см2) from 0,1 to 0,6

Temperature of process drains °С upto 30

Flow rate of process drains m3/h upto 6

Pressure of fuel gas at reduction unit inlet MPa (kgf/cm2) from 0,1 to 0,6

Temperature of fuel gas °С upto 30

Flow rate of fuel gas m3/h upto 3000

Ignition system power supply:- supply voltage- frequency

VHz

220±10* 50±1

*At a customer’s request the ignition system can be powered from 24V autonomous supply source.48 49

Atm

osph

eric

Bur

ner

Uni

ts

Atmospheric Burner Units

Designation

Intended to heat up intermediate heat carriers in industrial heaters operating at hydrocarbon production and refining facilities.


Can be used outdoors in mild climate conditions at following ambient parameters:

- temperature from -60°C to +70°C

- relative humidity upto 90%

- atmospheric precipitates such as rain, dew and fog

- altitude above sea level to 1000m

- seismicity upto 9 points

Climatic modification – any as per GOST 15150.

Design

The equipment comprises ejection type atmospheric burners with premixing. Primary and secondary air volume is adjusted by a damper. The assembly is equipped with a pilot burner to ignite the main burners at start-up or fire loss.

Scope of delivery

The scope of delivery includes:

- a casing

- main atmospheric burners

- a pilot burner

- a flame control system for the pilot burner

Rated thermal capacity, kW: 50 … 3000 at fuel gas pressure 0.05 … 1 kgf/cm2.

Atmospheric Burners

Atmospheric Burners

Designation

The burners are designed to heat up a gas or an intermediate heat carrier as part of process heating equipment at hydrocarbon production and refining facilities.


Can be used outdoors in mild climate conditions at following ambient parameters:

- temperature from -60°C to +70°C

- relative humidity upto 90%

- atmospheric precipitates such as rain, dew and fog

- altitude above sea level to 1000m

- seismicity upto 9 points

Climatic modification – any as per GOST 15150.

Rated thermal capacity power, kW: 50 … 3000 at fuel gas pressure 0.05 … 1 kgf/cm2

Design

Ejection type atmospheric burners complete with premixing function and a combustion stabilizer. Air intake volume is adjusted by a damper.

50 51

Noz

zle

burn

ers Designation

Enhancement of gas turbine plants in gas main compressor units through the modernization of combustion chambers by replacing the standard burners for nozzle-type burner units:

• lower hazardous emission of NOx, CO and reducedspecific flow of fuel gas;

• reducedunbalanceof temperature fieldupstream theturbine nozzle diaphragm and lower vibration near the fuel header.

Research targets

Gas compressor units with gas turbine plants (types as per Russian standardization system are ГТ-6-750, ГТН-6, ГТН-25-1) equipped with combustion chambers, where the burners serve for the following purpose:

• preliminaryformationofafuel-airmixtureupstreamtheburning zone:

• microflare double-zone burning, first with excess airratio of α<<1,then α>>1.

Results

Turbine plant type 6-750

NOx and CO of approximately 50 mg/st.m3 (at 15% O2), specific flow of fuel gas is lower by 4-5%, reduced unbalance of temperature field (ΔT=30°C achieved without fine tuning) and lower vibration near the fuel header by 10-15%. Faultless running time of more than 50,000 hours. 19 units were retrofitted in total (5 units – ordered by Gazprom Transgaz Ukhta, 12 units for Gazprom Transgaz Moscow and 2 units for OJSC UTW). The burner design and its arrangement on a combustion chamber is shown in the figure 1.

Turbine plant type 6

NOx reduced by 25%, obvious reduction of fuel gas specific flow (statistics required for quantitative estimation). The first experimental burner model is given in the figure 2. The combustion chamber retrofit with the purpose of secondary air redistribution in order to optimize the thermal balance upstream the turbine nozzle diaphragm has not been completed yet, but the results are encouraging (see fig. 3).

The specified gas turbine plants were started up in compliance with standard cyclic graphs.

A unique feature of nozzle-type burners is the fact that they are able to solve all the burning process concerns. Besides, they assist in development of an alternative burning procedure to minimize hazardous emission of NOx with initial excess air ratio of much higher than 1 (at a temperature of below 1,400°C, when nitrogen oxides are minimum). To implement this technical solution, it is required to supply the fuel gas to burners via two headers (some burners should operate during start-up, and others should join mode by mode, as for the types 750-6 and 10-4).

Nozzle burners

Upgrading temperature field of gas compressor unit type ГТН-6 No.11

Figure 1

Figure 2

Figure 3

52 53

Designation:

The enclosures are designed to pro-tect I&C instruments and valves against harsh environmental factors: cold, mois-ture, chemically active condensate, solar irradiation.

Design

There are two locks in the front sec-tion of an enclosure and two hinges in the rear section, which allows to open the cover to locate and install instruments. The edge of the cover along the perimeter is heat insulated. The enclosure is cov-ered and locked.

Some certain enclosure modifica-tions can have an inspection window for instrument reading. An explosion protect-ed heater can also be located inside.

Application

The enclosures are for outdoor usage in the oil and gas industry, in the mild (У1) and mildly cold (УХЛ) climatic areas, in the conditions suitable to meet category 1 as per GOST 15150, ambient temperature from minus 60°C to plus 45°C and relative humidity up to 100%, in explosion hazard-ous zones.

Weatherproof enclosures

Wea

ther

proo

f enc

losu

res

DesignationThe flare is designed for smokeless

burning of HP/LP waste gases and hydrogen-sulfide-containing gases, for ignition and permanent flame maintenance at pilot burners of a flare tip as part of an offshore platform flare system.

The unit operates over the ambient temperature range from -40°C to +40°C at marine climate conditions.

The flare equipment provides the following:

• pilot burner remote ignition inmanualor automatic mode;

• automatic gas pressure retention tofeed the pilot burners and the flame front generator;

• automatic switching the pilot burnersover to a propane back-up in case the fuel gas supply is lost.

The flare control unit provides:

• pilot ignition control in manual orautomatic mode;

• pilotflameavailabilitycontrol;

• pilotburner reignition incaseof flamefailure;

• flarecontrolanddatatransferfromtheupper level.

The flare control unit is equipped with emergency sound/light alarms to actuate in response to the following:

• pilotburnerflamefailure;

• fuelgaspressurefallattheflareinlet.


The flare comprises the following components:

1. Combined tip (2 tips: an HP tip and a combined tip for LP line and hydrogen-sulfide-containing gases);

2. Propane back-up;

3. Pilot/igniton burner piping network;

4. Valve station for gas, propane and compressed air lines combined with the flame front generator;

5. I&C and automatics.

Offshore Flare



Burned gas flow:- high pressure- low pressure- hydrogen-sulfide-containing gases

kg/hr8350...319034271...177011375

Burned gas pressure:- high pressure- low pressure- hydrogen-sulfide-containing gases

MPa0,1260,1100,110

Quantity of pilot burners nos. 4

Type of gas for pilot burners:- standard- back-up

Fuel gas as per GOST 5542-87technical propane as per GOST 20448-90

Max. gas flow to pilot burners- fuel gas- propane

st.m3/hr4020

Max. gas flow to flame front generator- propane- air

st.m3/hr10180

Gas pressure at pilot burner inlet MPa 0,2

Max. weight of equipment mounted on flare shaft kg 1750

The flare operates as follows:

Т0.4 MPa fuel gas is supplied from a treatment manifold to the valve station to reduce down to 0.2 MPa and to feed the pilot burners. The propane is fed from the back-up source to the flame front generator inlet, where it is reduced down to the required operating pressure and is further mixed with the compressed air thus forming a flammable gas-air mixture. This mixture fills the generator-burner connecting pipeline and is ignited by an electric spark plug by a signal from the control board. The connecting pipeline transfers the running fire from the generator to the ignition burners to start the pilot burners. The thermocouples inside the pilot burners send a flame availability signal to the control board. Then the gas and compressed air supply to the flame front generator is terminated, and the waste gas supply to the combined tip is permitted. The combined tip provides waste gas smokeless burning with a wide range of flow rates. The flare tip service life is 25 years due to the use of up-to-date heat-resistant steels and advanced technologies of waste gas recovery.

In case of emergency disconnection of fuel gas supply to the valve station inlet, the system automatically changes over to the propane back-up to feed the pilot burners. It is not required to shut the flare down when changing over to the propane supply mode and back.

The flare is delivered as a set of separated assemblies and fixtures to be assembled in the field.

Off

shor

e Fl

are

54 55

Designation

The containers are designed to transport and store various chemicals used in process of hydrocarbon production and injection of water to production facilities.

It may be applied in oil and gas production industries, at onshore supply bases, open decks of multifunctional supply vessels (ice breakers), at open decks of offshore ice-resistant stationary platforms when carrying out exploration and production works at oil and gas fields.

The design is a welded vertical cylindrical vessel with inner diameter of 2,300 mm, working capacity - 10 m3, enclosed into a welded metal frame. The vessel is rigidly secured by the frame elements.

The container is heat-insulated with an insulated substance applied onto its external surface. The substance is protected with a metal jacket against damages.

The vessel material is chromium-nickel steel, the frame material is low-alloy steel.

The container is equipped with an internal coil for steam heating when located at an onshore supply base, and also with a heating cable for electric heating when used at onshore supply bases, open decks of the vessels and the platforms. Instrumentation: a level indicator, a thermometer, a pressure gauge, nozzles with shut-off valves, breathers and safety valves.

In the bottom part there is a tray for leakage collection.

In the upper and lower corners of the frame there are fittings provided for weight-lifting devices (GOST 20527-75) to fix the container. In the upper corners of the frame there are lifting rings for transportation. The container is equipped with a stationary lifting fixture connected to the rings, which is never removed.

The item has a climatic modification “M” and the location category “1” as per GOST 15150-69. The item may be operated outdoors at the air temperature of -40°C to +30°C under various seasonal conditions at relative air humidity of 89%. The item should withstand the temperature as low as minus 46°C.

All in all there are two design versions differentiated by the type of transported chemicals:

Type 1 - for cargos not classified as «hazardous» as per international UN classification;

Type 2 – for “hazardous” cargos.

The container dimension type as per GOST R 50697-2004 – 1D.

According to the type of service and the Rules of Russian Maritime Registry of Shipping as of 2009, the container is related to offshore category and is covered by the requirements of the International Maritime Dangerous Goods (IMDG Code) of 2007, European standards EN 12079 of 2006, IMO MSC/Circ/860 as of May 22, 1998.

The thermally controlled container is equipped with a control system, making it possible to automatically maintain the temperature of chemicals within the specified range and to monitor the level.

Offshore Thermally Controlled Containers for Transportation and Storage of Chemicals

Off

shor

e T

herm

ally

Con

trol

led

Con

tain

ers f

or T

rans

port

atio

n an

d St

orag

e of

Che

mic

als

Main parameters and characteristics

Container type transport

Arrangement vertical

Container capacity, m3 10

Characteristics of chemicals and IMDG classification

Internal working pressure, MPaКМЕВ. 061634.331.00.000КМЕВ. 061634.331.00.000-01

0,00140,27

Temperature of transported medium, °C from 5 to 15

Container dimensions, LxBxH, mm (2,991+5 x 2,438+5 x 3,650+5)

Empty container weight, kgКМЕВ. 061634.331.00.000КМЕВ. 061634.331.00.000-01

4200±154300±15

Electric equipment

- current AC

- power supply, V 240

- frequency, Hz 50

- current strength, A 11.4

- maximum consumed capacity, kW, max. 4.2

- rated capacity, kW, max. 2.83

56 57

Designation

The heater with an intermediate heat carrier is designed for heating gas, oil and formation water and their mixtures for different process purposes at oil, gas and gas condensate fields.

It is designed as a skid and operates as follows: a fuel gas is supplied to a preparation unit (control cabinet), where after cleaning and reduction it is fed to a burner to be mixed with air and then burnt. Fuel gas combustion products are forwarded through a heating duct, give the heat to the intermediate heat carrier and are released through a chimney. Produced gas is coil heated from the intermediate heat carrier to gain controlled temperature range.

Heater type 350



Max heat power kW 350

Max efficiency by heated product kg/h 12000

Fuel natural gas as per GOST 5542-87

Max power supply, not more than kW 4,5


mm 650025008010

Max weight- empty- with intermediate heat carrier

kg 680012500

Climatic modification any as per GOST 15150-69

Hea

ter

type

350






Max power supply kW 4,5


mm 995028508010


kg 1300022500


Heater type 500-01

Designation

The heater with an intermediate heat carrier is designed for gaseous, liquid and mixed media, using natural gas as a fuel. It can operate at an ambient temperature from minus 50°C to plus 50°C.

The heater is designed as a skid with possible disassembling of its parts for current diagnostics and routine replacements. In particular it is possible to remove the coil and the heating duct out of the casing. Indirect heating is provided in a heat exchanging section that consists of a vessel (casing and expansion tank) filled with the intermediate heat carrier to transfer heating energy from the heating tubes to the product coil.

58 59

Designation

Heater type 500-02 with a heat power of 500 KW is designed for direct heating of a heat carrier to warm up process equipment of the inlet manifold unit and admin buildings of a preliminary gas processing terminal using natural gas as a fuel in conformance of the Russian GOST standard 5542-87.

Heater type 500-02

Hea

ter

type

500

-02



Rated thermal power of a burner unit KW 500

Heat carrier Ecotherm

Volumetric flow rate of heat carrier m/hour 12,5

Temperature of heat carrier: - inlet - outlet

°С30-7045-95

Pressure of fuel gas:- minimum- maximum

MPa0,61,0

Max flow rate of fuel gas м/час 57

Supply voltage V 220

Max heater weight- empty - filled with heat carrier

kg 800012200

Design service life years 30

Max overall dimensions mm, l-w-h 8200 х 2200 х 11000

60 61

Heater type 1000






Max power supply kW 1,7


mm 1316546308931


kg 3600068000

Climatic modification У1 as per GOST 15150-69

Designation

The heater with an intermediate heat carrier is designed to heat up a hydrogen sulfide mixture to prevent hydrates formation while it is throttled down to the required pressure. It performs the following functions:

- heating of a hydrogen sulfide mixture supplied from a well;

- remote measurement and adjustment of a gas mixture flow at standard temperature conditions, automatic cascade adjustment of the heated gas temperature to align with the intermediate heat carrier temperature in the heater vessel;

- reduction of high pressure of a hydrogen sulfide mixture down to an indicated temperature;

- fuel gas heating before and after the reduction;

- measuring the fuel gas flow rate with a multistage recording;

- multistage reduction of the fuel gas pressure down to an indicated parameter and precise pressure maintaining while changing the inlet pressure or the fuel gas flow rate;

- transfer of emergency and warning signals to the operator’s room.

Air

Hea

ter Designation

The recuperative type air heater is designed to warm up industrial premises, various equipment including block-boxes of gas compressor turbine drives for field pipelines

Air Heater


Parameter Unit ПВ400 ПВ400-01

Max. thermal capacity kW 400

Max. capacity by heated product m3/h 15000

Fuel natural gas as per GOST 554287

Max. power consumption kW 4.5

Overall dimensions- length- width- height

mm 255018003110

324019502888

Max. weight kg 1160 1250


Model ПВ400 on wheelsModel ПВ400-01 stationary

Two types are available:

DesignationThe steam generator is

designed to clean the units of gas/oil air-cooling units, blades of gas compressors and other equipment, mechanisms and facilities that withstand 200°C.

Steam Generator



Max. capacity kg/h 480


Max. power consumption kW 1.5

Overall dimensions- length- width- height

mm 270017301540

Max. weight kg 1200


62 63

Gate valve 100х140

Designation

The valve is designed as an isolation device for X-mas trees, wellhead equipment and well piping to completely isolate or release a working stream.



Nominal pressure МПа 14

Working temperature range °С from minus 60 to plus 120

Working medium oil, gas, gas condensate, water

Hydraulic control fluid Polymethylsiloxane hydraulic fluid type «PMS-20-Yugra» as per specification TU 2229-002-94483128-2007

Climatic modification as per GOST 15150 ХЛ1

Hydraulic control pressure range MPa 9…21

Max closing time с 12

Hydraulic control line connection thread as per GOST 28919

Max hand wheel force N (kgf) 450 (45)

Flanges GOST 28919

Valves

Valv

es

Valves

Vales are intended for use in the piping of oil, gas and gas condensate wells and at other hydrocarbon production, transportation and refining facilities.

Control valves Designation:

Control valves are designed to control a working medium flow rate.

Two trim variations are available: straight through and angular.

The locking member is a perforated ball. The separator inside the ball has apertures closable by a cylinder.

The actuating mechanism can be hydraulic straight type, hydraulic rotary type, pneumatic, electric straight type, electric quarter turn type.

Valve working pressure - 10 to 70 MPa

Nominal diameter – 50 to 400 mm

Working medium – liquids and gases containing hydrogen sulfide and carbon dioxide

Working temperature range – from -60 to +100°C

Connection type – flanged.

64 65

Non-Return Isolation ValvesDesignation:

Designed for transportation and automatic isolation of a pipeline as the gas pressure exceeds the critical value. The valves can operate indoors as well as in the open air.

Climatic modification, placement category – any as per GOST 15150.

Working pressure – from 4 to 63 MPa.

Nominal diameter – from 50 to 150 mm.

Working medium – natural gas.

Working temperature range – from -60 to +100°C.

Connection type – flanged.

Valv

es

Shut-off valvesDesignation:

Valves are designed to manually stop the medium flow in a pipeline.

Operating pressure – from 4 to 70 MPa.


Operating medium – liquid and gaseous hydrocarbons, oil, oil products, as well as other liquids and gases, where a construction material corrosion rate is not more, than 1mm/30 years.

Operating temperature range – from minus 60 to plus 100°C.

Shut-off class – A as per GOST P 54808.

Connection type – flange.

Needle valvesDesignation:The valves are installed in a X-mas tree, wellhead equipment,

pipelines and BOP equipment and used as isolation devices.

Operating pressure – from 4 to 70MPa.

Nominal diameter – from 2,5 to 8 mm.

Operating medium – oil, gas, gas condensate and their mixtures, as well as containing CO

2 and H

2S.


Corrosion proof class – K1, K2, K3 GOST 13846.


Check valvesDesignation:Valves are designed to automatically prevent reverse flowing of an

operating medium.

Different trims are available such as straight through and angular.

Gate sealing material – elastomer, metal-metal.

Operating pressure – from 4 to 70 MPa.


Operating medium – liquid and gaseous hydrocarbons, oil, oil products, as well as other liquids and gases, where a construction material corrosion rate is not more, than 1mm/30 years.



Connection type – flange.

ValvesValves

66 67

Quick-Detach Restriction Device

The restriction device with a flange tap-off serves as a primary transducer to measure the gas flow by a variable pressure drop at discharge measurement stations as per GOST 8.563.1-97.


Parameter Type

УСÁÔ УСÁÔ2 УСÁÔ3 УСÁÔ4

Nominal diameter, mm 100 300 300 300

Working pressure, MPa 16 6.3 10 16

Pressure tap-off method through flange

Diameter of diaphragm opening, mm customized

Ambient temperature, °C – 60 to +55

Climatic modification УХЛ1

Qui

ck-D

etac

h R

estr

icti

on D

evic

e

Frost resistant downhole check valvesDesignationThe valves are designed to release excessive

gas pressure from an annular space and formation fluid takeoffs of wellheads. Due to continuous washing of the locking member with a warm transported medium, the valves secure a reliable continuous operation of wells at any negative ambient temperature. The valves operate in unattended and self-contained mode.

Design and operationThe formation fluid flows through the cavity in the valve body, washes and therefore warms up the body, seat and the plate of

the valve, thus maintaining the required temperature.

As the gas mixture arrives at a pressure higher than that of the formation fluid by 0.02 – 0.05 MPa, it moves the valve plate lengthways that entails the gas to exhaust along special channels into the valve body and further into the pipeline.

Since the gas mixture pressure reduces inside the valve body, the plate is spring returned to the seat to isolate the gas flow.

Climatic modification – УХЛ1 as per GOST 15150.

Working pressure 0 14.21 MPa.

Nominal diameter of wellhead connection – 65, 80, 100 mm.

Nominal bore – 10 – 20 mm.

Working medium – oil well products, mineral oil, water, natural gas.

Drained medium – gas mixture.

Valves

68 69

Hydraulic Pressure Intensifier type M4, M7

Designation

The hydraulic pressure intensi-fier is designed to boost operating pressure at its outlet compared to the inlet.


М4 М7

Max inlet pressure, MPa 10 10

Max outlet pressure, MPa 40 70

Pressure boost ratio 4 7

Operating temperature range, °С from minus 40 to plus 80

Capacity at 1 cycle/sec, l/min 1,1 0,62

Operating medium - Polymethylsiloxane hydraulic fluid type «PMS-20-Yugra» as per specification TU 2229-002-94483128-2007- Hydraulic oil PANOLIN POLAR 5

Climatic modification as per GOST 15150 У1

Connection thread - inlet and drain - outlet

G1/4”-A as per GOST 6357 maleK1/4” as per GOST 6111 female

Max overall dimensions, mm

- length 270

- width 105

- height 105

Max weight, kg 15

Valv

es

Subsurface Safety ValvesDesignation

The subsurface safety valve is designed for the controlled tight isolation of the production string (tubing string) at gas and gas-condensate wells in emergency or normal operation which require to isolate the bed from the well head.

Design and operationа

The valve is designed as a subsurface normally closed valve controlled from the surface by pressurizing the valve hydraulic chamber with the control fluid.

The valve comprises a spring body 1, which contains the following components screwed on either side - a seat body 2 and a stuffing drum 3, in which a flow tube 4 moves, having an upper flow tube 5 and a flow nipple 6 (hereinafter referred to as the flow tube) on each end.

The upper flow tube 5 is arranged in the form of a differential piston and forms a hydraulic chamber 7 together with a cylindrical bore in the stuffing drum 3, and holes 8 and 9 connect the chamber to the hydraulic control line.

The isolation tightness is secured with a spring-loaded gate 10, which is installed on a rotation axis and is pressed to the gate seat 11 with a torsion spring

The valve operates as follows

When the control chamber 7 is not pressurized or when there is low pressure of the control fluid (see the figure), the flow tube is pressed to the end of the chamber 7 forced by the spring 14 via a set of support rings 12 and a support bush 13.

Whenever the chamber 7 gets pressurized, the flow tube moves towards the gate 10 overcoming the force of the spring 14, and opens it.

When the pressure in the chamber 7 goes down to the specified value, the spring 14 returns the flow tube to the initial position, and the torsion spring together with the well gas pressure press the gate 10 against the gate seat 11, thus closing the valve.

Two modifications of the valve can be delivered: a subsurface safety valve screwed to the tubing string, and a subsurface safety valve installed into a seat nipple together with a lock.

The valves are designed for the tubing string diameters from 78 to 127 mm and for a working pressure from 21 MPa to 70 MPa

.

Downhole Equipment

Valve in seat nipple with lock

Safety valve with lock

Threaded safety valve

70 71

Design

The devices consist of:

- Pipeline in accordance with the design pattern

- Sampling cylinder (if required).

Sampling device SC-1

The system is a pipeline with two circuits. The first circuit consists of a control valve, check valve and a wedge valve to forward the stream into a closed drain loop. The second circuit consists of pressure gauges, needle valves, quick connections and a sampling cylinder.


The system is a pipeline with a heat exchanger and two circuits. The first circuit consists of a control valve, check valve and a wedge valve to forward the stream into a closed drain loop. The second circuit consists of pressure gauges, needle valves, quick connections and a sampling cylinder.


The system is a pipeline with two circuits. The first circuit consists of a control valve, check valve and wedge valves (shut-off valves) to forward the stream into a closed drain loop. The second circuit consists of pressure gauges, needle valves, quick connections and a sampling cylinder.


The system consists of a wedge valve and a ball valve.

Operating restrictions

The systems can be operated outdoors at a temperature from -40°C to+30°C in any weather conditions with relative air humidity 89% and at areas liable to flooding.



Sampling Devices

Designation

Designed for taking samples of working or process liquids from lines.

The system is a pipeline with control and isolation valves and a sampling cylinder mounted on a frame.

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Sampling medium

Sampling cylinder nominal volume, l

Dimensions, mm

We

igh

t, k

g

ISC43001 SC-1

0,1

0,35

From -10 to +50

From -10 to +75

From -40 to +30

Oil containing water

1,0

1560х667х1700172

ISC43003 SC-1 1,5From -2 to + 50

ISC47001 SC-2 2,0 2,5From -10 to +60

Oil 1435х985х2055 313

ISC10001 SC-52,0 21,19

From -40 to +30

Formation fluid

0,5 2280х665х1707395ISC10002 SC-5

ISC48005 SC-50,105 2,5 Cooling agent

ISC48006 SC-5

ISC31001 SC-7

0,563

1,03From -10 to +50

Cooling agent - 850х270х16031ISC31002 SC-7

ISC30520 SC-50,6

From - 40 to +50

Process hydrocarbon liquids

1,0 2010х600х1670 132

SC-1 sampling system SC-2 sampling system

Sam

plin

g D

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72 73

Designation

The hydraulic actuator is designed to turn a ball valve to open/close positions.

Ball valve hydraulic actuators


Actuator type Hydraulic, rotary, quarter turn, bidirectional actuator

Control mediumPolymethylsiloxane hydraulic fluid type «PMS-20-Yugra» as per specification TU 2229-002-94483128-2007

Nominal diameter of a ball valve to be connected 80 100 150 200

Control pressure range, MPa 5…10

Maxtorqueatanoutputshaft,N∙m 1100 2700 4100 10000

Max design response (open/close) time, sec 6 6 9 9


Ball valve connection elements Flanges as per GOST R 55510

Max overall dimensions, mm:- length- width- height

450310340

660430370

660460410

730530500

Max weight, kg 65 125 160 285

Designation

NC hydraulic isolation valve is designed for automatic isolation of a process pipeline when the pressure decreases/increases beyond the prescribed limit, when the temperature increases (fire) in the area where the valve is installed. It also actuates in response to the remote control signal.

The valve can be reset open manually by means of a hydraulic pump being a part of the valve.

Hydraulic isolation valve


Operating mediumOil, gas, gas condensate, water with CO

2 not more

than 6%

Nominal diameter, mm 80

Max operating pressure, MPa 70

Operating temperature range, °C from minus 60 to plus 100

Complete closing time, s not more than 12

Connection type flange

Control fluid Hydraulic composite fluid

Bal

l val

ve h

ydra

ulic

act

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74 75

Pneumatic plunger type pump unit

Designation

The pneumatic plunger type pump unit is designed for volumetric forcing supply of neutral and aggressive fluids at low flows and a wide pressure range.


Operating medium - pump - drive

Corrosion inhibitor – methanol from 60 to 99%Compressed air

Temperature, °С - operating fluid of pump, drive - ambient

from minus 60 to plus 70from minus 60 to plus 45

Connection - fluid - air

K1/4” as per GOST 6111-52K1/4” as per GOST 6111-52


Max outlet fluid pressure, MPa (kgf/cm2) 80 (800)

Gas pressure, MPa (kgf/cm2) 0,14 … 1,4

Fluid flow rate, l/h 0,05 … 7,6

Number of cycles per 1 minute 0,5 … 105

Max overall dimensions, mm - length - width - height

370170170

Max weight, kg 6

Equipment for Nuclear Power Industry

Montejuses

Diesel fuel tanksStem penetration embedments

Engineering and production of equipment for nuclear power plants has been a prospective busi-ness area for the KOSMOS-NEF-GAS HOLDING since 2008. For the moment all the approving li-censes and documents has been obtained.

Personnel training and process preparation

The staffs of the KOSMOS-NEFT-GAS under-go periodical training and qualification to manufac-ture nuclear industry products.

Our welders are certified in accordance with Russian Nuclear Engineering Code PNAE G-7-003-87. Welding and overlay processes have been approved by the head material organization NIKIMT ATOMSTROY. The welding and overlay technologies are certified accordingly as per PNAE G-7-010-89 covering all thickness ranges of car-bon and austenitic steels.

Welding quality is strictly controlled at all stages of equipment manufacturing procedures. Our NDE laboratory is equipped with all the modern examination means. The laboratory specialists have been qualified in accordance with PNAE G-7-010-89 to carry out visual, dimension, penetration, X-ray and ultrasound examinations. Test specimens are examined by certified experts emplying destructive test procedures on modern equipment.

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unit

76 77

Product list

The products engineered and manufac-tured for nuclear power plants have been li-censed as:

1. Valves including remote controls, as per NP-068-05, certified as the 2nd and 3rd safety classes as per OPB 88/97, for control and metering purposes with dif-ferent working media

2. Pipe fittings, group B and C as per PNAE G-7-008-89, to be used as separate parts or assemblies to complete pro-cess pipelines and to connect pipes and equipment

3. Vessels and heat exchanging equip-ment, group B and C as per PNAE G-7-008-89 to operate pressurized or in vacuum for collecting, cleaning, heating or cooling (condensating) of different working media.

4. Construction steel (embedments, con-tainers, fixtures, ladders, platforms) certified as the 2nd and 3rd safety class-es as per OPB 88/97.

5. Low voltage switchgears, distribution boxes, cabinets and control panels.

Current supplies

Since 2009 we have developed and been manufacturing the following equipment for the NovoVoronezh NPP 2 (power units 1 and 2):

- 1m3 to 10m3 tanks and vessels for radio-active water treatment

- 10m3 to 40 m3 tanks and vessels for aux-iliary buildings

- stem penetrations with different lengths and torques for reactor side sealed premises

- 0.4 m3 to 300m3 tanks and vessels for diesel fuel and oil storages

- primary and secondary sampling heat exchangers and trays

- service water valves

- electrical boards

Blow-down expansion vessel

Condensate tank

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Over the period from 2010 to 2012 we have engineered, manufactured and supplied a com-plete package of high pressure pipelines for the third unit primary and secondary circuits of the Rostov NPP.

Advanced development

The KNG experts have developed the follow-ing equipment for nuclear power plants:

- ion exchange and mechanical filters

- plate and shell-and-tube heat exchangers

- hydrocyclones and ejectors

- custom fabricated metals and embedments

Sampling traysSampling heat exchangers

Stem penetrations

78 79

Equipment for Nuclear Power Industry

Designation

The blender is designed to prepare fracturing fluids (gels), mixtures based on these fluids and a solid granular component (proppant) and to supply the mixture into high-pressure pump units included into mobile hydraulic seam fracturing complex at oil and gas fields.

The blender performs the following main functions:

• receiving the proppant from a granular component unit;

• dosing the proppant to a double-phase mixer pump;

• dosing liquid additives;

• dosing a dry additive;

• online weighing the dry additive in a hopper and transferring the data into a monitor and control machine of the complex;

• preparation of working fluids both in process of getting ready for hydraulic fracturing and actually during hydraulic seam fracturing while the fluid is being mixed with the proppant;

• mixing the working fluids (gels) with the proppant;

• supplying the working fluids and mixtures into HP pumps.

Design

The blender equipment is mounted onto a truck chassis model MAZ-63031.

Blender

Ble

nder

Technical specificationParameter Unit Type АПС-6 Type АПС-3

Flow of working fluid (mixture) through the blender m3/min 0.3 – 0.6 0.3 – 3.0

Gage pressure at the blender outlet MPa 0.4 – 1.0 0.4 – 1.0

Number of liquid additive bins nos. 2 2

Capacity of each liquid additive bin m3 1.0 1.0

Total capacity of proppant receiving bin m3 0.3 0.15

Flow of proppant through one duplex mixing pump t/min 0.1 – 4.0 0.1 – 4.0

Flow of liquid additives l/min 0 – 40 0 – 40

Flow of bulk additive kg/min 2.5 – 5.0 2.5 – 5.0

Maximum concentration of proppant in mixture kg/m3 1,800 1,800

Number of branch pipes:- discharge header- suction header

nos.712

46

Inside diameter of branch pipes mm 100 100

Control of operating mechanisms electric hydraulic manual

Gate actuator:- suction header- discharge header

hydraulicmanual

manualmanual

Operating mechanism actuator hydraulic hydraulic

Drive of hydraulic power unit diesel type ЯМ33238Д1

from truck engine

Power supply to the blender units V from power unit 26.8-29.7

from chassis 26.8 – 29.7

Length:- when in transport position- when in operation position

m10.811.4

9,810,0

Width m 2.5 2.5

Height m 3.9 3.2

Weight t 22.0 18.0

Speed and cross-country capacity as for basic chassis

Design and operationThe blender comprises the following systems and components:

• avehicle–atruckmodelMAZ–63031;• aduplexmixingpumpsystem;• ablenderunithydraulicdrive;• anoperatorsupportsystem;• asystemforheatingtheliquidadditivebins;• aproppantfeedingsystem;• asystemofliquidchemicalfeedandmake-up;• asystemofdrychemicalfeed;• apowerunit;• amonitoringandcontrolsystem;• anelectricequipmentsystem;• valvesandpipelines;• sparepartsandaccessories.

All units and assembly components of the blender are mounted on two frames:• onastationaryframeinstalledandfixedtothechassisframe;• onaliftingframe,whichishingedlyconnectedtothestationaryframe.Duringtransportationtheliftingframeisblockedwithclamps.

The lifting frame is turned to a working position by a single hydraulic cylinder fixed to the stationary frame.

The stationary frame comprises the following components:• liquidadditivebinsheatedwiththetruckengineexhaustsorthepowerunit;• hydraulicallydrivenplungerpumps;• receiversoftheliquidadditivefeedsystem;• flowmetersforliquidchemicals;• thepowerunit;• hydraulic drive components: a hydraulic tankwith a fixedhydraulic station; a distributing reductiongear equippedwith hydraulic

pumps and actuated by the power unit engine; a hydraulically driven oil cooler with a fan, hydraulic distributors, two hydraulic supports;• ahydrauliccylindertoliftamixingunit;• asingle-seatoperator’scabin,heatedwithacoolantofthepowerunitengineorchassisengine;• asystemforheatingtheliquidadditivebins,tofeedthehotgases(fromthepowerunitengineexhaustpipe)toliquidadditivebins,

comprising pipelines and four manually-controlled dampers for gas distribution;• asuctionheaderwithtwelvebranchpipesandhydraulicallycontrolleddampersarrangedontherightalongtheflow;• adischargeheaderwithsevenmanuallycontrolleddampersandbranchpipes,fiveofwhicharearrangedalongtheflowontheleft,

and two – on the right;• devicestomeasureapressure,flow,workingfluiddensityandtheproppantconcentrationinthemixture;• liftingmechanism;• railedserviceplatforms.

The lifting frame comprises a mixing unit, which includes the following components:• aduplexpumpequippedwithhydraulicmotorsanddampers;• hydrauliccylindersfordampercontrol(acylinderalsocomprisesahandleformanualdampercontrol);• proppantbins;• adrychemicalbin(adispenserisequippedwithmanualcontrolofdrychemicalflow);• manuallydrivenvalves;• distributionunits.

All units of the blender and hydraulic drives are interconnected with pipes and flexible hoses. Mains and liquid additive feed manifolds include make-up, isolating and drain valves.

When preparing the working fluids, the reservoir with clear fluid (water, oil, diesel fuel) is circuited from the outlet to the inlet through the blender by means of LP hoses. The blender circulates the fluid. When in the process of circulation, the required liquid/dry chemicals are mixed with the main fluid to convert it into a gel. The gel is circulated to obtain the viscosity sufficient for hydraulic fracturing.

For hydraulic seam fracturing, the necessary number of working fluid reservoirs is connected via the LP manifold hoses to the inlet header of the blender, whilst its outlet header is connected to the LP pumps. During the fracturing process the working fluid (gel) is taken from the reservoirs (blender driven) and fed to the HP pumps. When pumping, the proppant (along with all the necessary liquid/dry chemicals) is mixed with the working fluid to reach the concentration sufficient for the process of hydraulic fracturing.

KNG is the original designer and the manufacturer of the blender.

Operating conditionsThe blender is designed to operate outdoors in the areas of mild climate conditions rated “У1” as per GOST 15150, at an ambient

temperature from -40°C to +50°C and relative humidity of 95-3% at 35°C.

80 81

1 2

76

3

4

5

Granular Component Unit

Designation

The granular component unit is designed for proppant transportation, short-time storage and supply into the blender receiving bin as part of a mobile hydraulic fracturing complex at oil and gas fields.

The unit performs the following main functions:

• proppanttransportation;

• proppantdosing;

• online weighing the proppant in bins andtransferring the data into a monitor and control machine of the complex;

• liftingthebinintoworkingpositionwiththehelpofhydraulic cylinders from a truck’s hydraulic system;

• lifting the bin into working position with the helpof hydraulic cylinders from an auxiliary hydraulic system with an electric drive (without the mover’s hydraulic system);

• additional loading the bin compartments withthe proppant from bags by means of auxiliary lifting-and-handling equipment, when the bin is in horizontal position.

Design

The unit equipment is mounted onto a truck chassis model MAZ-642208 with a dumping semitrailer model MAZ-9506.

Operation

The granular component unit is manufactured on the basis of a serially produced dumping semitrailer model MAZ 950600-010.

The main tractor vehicle is a truck model MAZ 462208.

The proppant is loaded in the bin via the loading devices with the help of auxiliary lifting-and-handling equipment.

The proppant is discharged and its flow is controlled by means of dampers. The proppant is fed from the bin compartments into a distribution bin and further to a receiving bin of the blender.

Due to higher volume of the bin (as compared to the available semitrailer body) the second hydraulic cylinder is provided. The hydraulic cylinder fixing points are moved to wing spars of the semitrailer frames.

On the rear side of the semitrailer frame there is a crossmember to which the outrigger cylinders and screw supports are fixed. The outrigger cylinders and the body lifting cylinders are controlled both from the truck hydraulic system and the auxiliary hydraulic system with the help of a hydraulic distributor installed on the left wing of the semitrailer.

On the front side of the frame the auxiliary hydraulic system is bracketed comprising an oil tank, an electrically driven hydraulic pump and distributors. A power cable is used to energize an electric motor of the auxiliary system pump. A cable drum is located in a box fixed to the left side of the semitrailer frame.

The additional hydraulic system moves the outrigger hydraulic cylinders and lifts the body without the truck hydraulic system.

The granular component unit comprises three pressure sensors to monitor the proppant weight and flow when the bin is in working position. One sensor is inside a line feeding the oil the bin lifting cylinders, the other two are screwed into the hydraulic pads of screw supports. The sensors generate 4-20 mA signals to send along a data cable into the monitoring and control machine, where they are converted to the proppant weight data.

KNG is the original designer and the manufacturer of the granular component unit.


The unit is designed to operate outdoors in the areas of mild climate conditions rated “У1” as per GOST 15150, at an ambient temperature from -40°C to +50°C and relative humidity of 9±53% at 35°C.



Transported proppant weight t 20.0

Maximum loaded proppant weight t 40.0

Capacity of bin compartments:- first- second- third

m3 2,04,015,0

Proppant bulk density t/m3 1.95

Size of proppant granules loaded into compartments:- first- second- third

nos.inch

16-2016-3020-40

Maximum flow through every compartment gate at proppant normal humidity

t/min 4.0

Compartment unloading sequence third, second, first

Soil bearing capacity under supports kg/cm3 2.0-2.4

Period of proppant storage in a bin, 20 tons days 2-3

Period of proppant storage in a bin, more than 20 tons, max hour 3.0

Time in lifted position, max hour 2.0

Hydraulic station electric drive power supply V 380

Length of hydraulic station drive power supply cable m 50

Overall dimensions in transport position, max- length- width- height

m20,02,54,0

Maximum weight in transport position t 42.0

Back angle of departure degree 23.0

Dumping angle, max degree 50.0

Ground gradient to install the granular component unit, max. degree 5.0

Driving speed and flotation as for basic chassis

Gra

nula

r C

ompo

nent

Uni

t

1-truck, 2-hydraulic cylinders, 3-proppant bin, 4-rear crossmember, 5-damper controls, 6-semitrailer, 7-auxiliary hydraulic system

82 83

Designation

The flare control unit (FCU) is designed for the operation together with vertical as well as horizontal type burning devices; it supervises the flame presence and provides the flare ignition in three modes: manual, automatic and interface control RS-485, using MODBUS RTU report.

The following design options are available:

• Ignitionby“runningfire”,themodificationsarefrom1till6thermal couples, as flame control transmitters;

• Electrospark ignition,one-and twochannelswith ionizedcontrol transmitters of the flame, integrated into the burner electrode construction;

• Combined ignition, combining “running fire” andelectrospark ignition, for the highly responsible applications.

The unit explosion protection is provided by the explosion protected box of “flameproof enclosure” explosion protection class with an explosion protection marking 1ExdIIBT6 and meets norm requirements in accordance with GOST 51330.1-99 (МЭК 60079 1 98), GOST 12.2.007.0 75, GOST P 51330.0 99 (МЭК 60079 0 98).

FCU is designed for the application at the following conditions:

Ambient air temperature from minus 60 up to plus 60 °C

Relative humidity up to 98% at air temperature up to 40 °C

Atmospheric pressure from 630 up to 795 mm of mercury column

Technical data

Control range of the flare flame lowest temperature is from 373 up to 1273 °K (from 100 up to 1000 °C).

Output voltage of AC, supplied to high voltage unit and electromagnetic valve, is from 198 up to 242 V at frequency from 49 up to 51 Hz.

FCU power supply is provided by AC net with dead-grounded neutral at voltage from 198 up to 242 V and frequency from 49 up to 51 Hz.

Power, consumed by the unit from the net is:

- at stand-by – 15 VA max.

- when the electromagnetic valve is on and ignition – 100 VA max.

The FCU mass is 50 kg max.

The FCU overall dimensions are (mm):

Height – 470;

Width – 497;

Depth – 335.

The FCU is designed on the production controller base, contained inlet channels of analog signals and inlet-outlet channels of digital signals. The controller, power unit and other subcenters are located inside explosion protected enclosure (1ExdIIBT6 protection class). On the enclosure cover the control elements, power indicator of the electrical valve, power indicator of high voltage unit and two indicators of flame presence.

Flare control unit

Flar

e co

ntro

l uni

t Designation

The high voltage unit ÁЗГ – 02 is designed to ignite the air-gas mixture in the flare system complex and has the following design options:

• “runningfire”ignitionsystemwiththehelpoftheignitionfuses, one- and two channels modifications;

• fortheelectrosparkignitionsystemwiththeintegratedcontrol indicators of ionized type flame, one- and two channels modifications.

The unit explosion protection is provided by explosion protected box of the “flameproof enclosure” explosion protection class with an explosion protection marking 1ExdIIBT5 and meets norm requirements in accordance with GOST 51330.1-99 (МЭК 60079-1-98), GOST 12.2.007.0 75, GOST P 51330.0 99 (МЭК 60079-0-98).

БЗГ – 02 is designed for the application at the following conditions:

Ambient air temperature from minus 60 up to plus 60 °C

Relative humidity up to 98% at air temperature up to 40 °C

Atmospheric pressure from 630 up to 795 mm of mercury column

Technical data

ÁЗГ – 02 contains one or two channels and works und the FCU control.

The electrodes voltage (with 4.5 mm clearance) is 12.5 kW.

The unit remains servicing at AC power supply change from 198 up to 242 V at frequency from 49 up to 51 Hz.

Consumable power from the FCU, does not exceeds 30 VA (for one channel) and 60 VA (for two channels).

The unit continues operating time is not more than 20 seconds with the following pause which is not less than 1 minute.

The unit mass is not more than:

- the design for “running fire” ignition – 9 kg;- the design for electrospark ignition – 30 kg.

The unit overall dimensions are not more then:- the design for “running fire” ignition – 207x187x117 mm;- the design for electrospark ignition – 365x360x225 mm.

High voltage unit

Option with «running fire» ignition

Option with ionized flame control sensors

84 85

Since 2010 the KOSMOS-NEFT-GAS Holding has been a system integrator of the SCADA platform “KNG ICS” by ETM Professional Control GmbH, a part of Siemens AG.

In 2015 KNG has certified KNG ICS – a proprietary SCADA system based on the KNG ICS.

“KNG ICS”Integrated SCADA/HMI system for automated process control, utility metering and production control

The system supports redundant distributed server systems to secure high reliability and safety. Integrated industrial protocols i.e. IEC, OPC, Modbus and Profibus to connect various peripheral equipment and a PLC with no relation to its manufacturer.

DesignationKNG ICS has been designed for software development in on-line process control, data acquisition and visualization systems.

DescriptionThe system is developed specifically for process automation solutions in oil and gas production facilities, dispatching and

planning systems. KNG ICS is an object-oriented client-server SCADA platform with standard software packages and generally accepted protocols. The system is a cross-platform solution and supports up-to-date operating systems i.e. MS Windows, UNIX, Linux, Solaris. KNG ICS is a flexible package scalable from mini-systems at an operator panel level to geographically distributed systems (MES) and production planning (PPS), including upto 10 million tags.

“KN

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con

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Composition

The system comprises the following components:

• GEDIintegrateddevelopmentand engineering environment;

• 10gOracledatabase;

• VISION real-time executiveenvironment;

• PARAdatabaseeditor.

The system has been widely adopted in Europe, China, and is also used at Gazprom facilities.

Nowadays, the SCADA systems are not only used for monitoring and control, but they also serve for process and business optimization. To solve this task, KNG ICS provides a software for simulation, fault detection, calculation of routes, planning and trading.

Using standard databases for historical recording any process and working data, KNG ICS provides access to these data for further business applications and users.

WinCC OA has been certified in conformance with IEC 61508 SIL3

86 87

Designation

LCP2-1 is a self-contained automatic station designed to control and monitor various electronic equipment and power plants located at gas wells, to transfer data to the upper automation level and to receive control commands.

The panel performs the following functions:

• acquisitionofdatafromsensors,transducersandactuatingmechanismsinstalled in a well, gas heater and flares

• generatingcontrolsignalsforactuatingmechanismsofawellequipment

• transferringwellequipmentoperationdata,contingencyandemergencysituations to the operator’s panel and the upper control level

• internalequipmentdiagnosticsandprovidingfailuresignals.


The panel is based on a twin door cabinet by Rittal. The lower part of the cabinet provides external cable and wire connections via vertical trays. The doors are equipped with lockable handles. There is a lamp above the doors to illuminate the entire cabinet or its parts in adjustable mode.

All the electronic devices and assemblies are mounted on an internal board for easy overview and quick replacement of defective elements.

The operator’s console MagelisXBTGK 5330 is located on the left side wall.

The Quantum controller by Schneider Electric is used in the panel with I/O modules. The controller is located on a rack with special coating for harsh environments. The modules are also environment protected.

Intrinsic safety barriers are used to connect sensors and actuating mechanisms operating in explosive zones. Lightning barriers are intended to protect all I/O channels against a lightning discharge.

The operator’s console displays the facility information and progress data and provides local control.

Local Control Panel LCP2-1

Loca

l Con

trol

Pan

el L

CP

2-1



Power supply V 19.2 … 28.8 V DC

Consumption current A 16 max.

Overall dimensions (width x height x depth)

mm 1200 x 2000 x 500

Weight kg 300 max.


The panel is used for continuous round-the-clock service in a climate controlled premise excluding moisture condensation and direct sun rays (E-house) away from vibration sources, explosion hazardous zones.

The following climatic conditions shall be met:

• ambienttemperaturefrom5to44°C

• relative air humidity from 10 to 80% (withoutcondensate separation)

• ambienttemperatureforstoragefrom-20to+70°C

• relative air humidity for storage from 10 to 95%without condensate separation

Climatic modification – УХЛ 4 as per GOST 150150-69.

88 89

19” BOX IPCP-01 with Hirschman Equipment and IP

DesignationThe box is designed to connect various devices to Ethernet

network, including terminal equipment and IP telephony devices.


The box comprises the following components:

• twocontrolledFastEthernetswitchboardsofthesecondlevelby“Hirschman”;

• IP-media-gateway;

• DECTbasicstation;

• an8dBdirectionalantenna;

• twojunctionnetworkpanelstoconnectfibre-opticcables;

• MOBILE200REFLEXEShandset;

• ahandsetchargingdevice;

• boxovervoltageprotectiondevices.

• устройствадлязащитыаппаратурыбоксаотперенапряжения.

Each of two switchboards is a multi-port device allowing to combine several separate segments into a single network. Each switchboard has two manifold ports SMT (SC socket type) designed to connect the switchboard to the network manifold (or to another switchboard) via fiber optics. The remaining 6 ports of the switchboard arranged as per 10/100Base-TX c/w sockets RJ-45 serve to connect terminal devices or independent network segments. The switchboards support any busbar, star topologies, ring-type structures (Hiper-Ring, RSTP).

The IP-media-gateway converts digital signals into Ethernet-packages. The IP-media-gateway can connect up to 4 devices (DECT basic stations or TDM-phones) to the Fast Ethernet network. The IP-media-gateway has a single port 100Base-TX.

Each junction network panel comprises 24 sockets to connect fiber optic cables.

The DECT basic station (4070 IO IBS) is connected to the IP-media-gateway. The basic station is indoor wall-mounted and is energized via the IP-media-gateway. The basic station coverage area is 50 m to 300 m depending on the location and ambient conditions. The basic station comprises an inbuilt antenna, and also a lead to connect any external antennas.

The 8 dB directional antenna is designed for external use and may be connected to the basic station.

Box, open front door view

Box

Basic station

19”

BO

X IP

CP-

01 w

ith

Hir

schm

an E

quip

men

t and

IP

DesignBoth the switchboards, IP-media-gateway and junction

network panels are installed into a standard cabinet by «Rittall». It also contains the devices to protect the box equipment against overvoltage.

The DECT station and 8 dB directional antenna are installed outdoors.

The cabinet is a 3-sectional wall structure. The two doors provide free access to the box internals

Basic technical specifications

Number of controlled Fast Ethernet switchboards RS20-0800S2S2SSDAE 2

Number of manifold SMT ports (SC type) per each switchboard (total in box) 2 (4)

Number of 10/100Base-TX ports (RJ-45 socket type) per each switchboard (total in box) 6 (12)

Number of DECT stations included in box 1 (4070 IO IBS)

Basic station coverage area 50…300 m

Maximum quantity of devices which may be connected to IP-media-gateway2 basic stations DECT or PWT or 4 terminals Reflexes

Power supply:9.6…60 V DC (for switchboards)198…242 V AC, 50 Hz (for IP-media-gateways)

Maximum consumed power:- 9.6…60V DC, W- AC, 50 Hz, W

16150

Ambient temperature for operation

For box and basic station, °C 5…30

For external antenna, °C -40…+80

Dimensions (HxWxD)- box, mm- basic station, mm- external antenna, mm

800х600х600215х170х45108х95х32

Weight- box, kg- basic station, kg, max.- external antenna, kg

700,350,11

External antenna Handset with charging device

90 91

Designation

The LV switchgears are used to receive and distribute electric power in DC and AC networks with solidly grounded or insulated neutrals up to 1000V and 50-60 Hz to equip electric equipment and to protect it from short-circuits and overloads as well as for commercial accounting of power consumption.

The switchgears are used as a part of pow-er supply systems, power distribution stations, control and power supply cabinets, emergency supply boards and to control various automatic equipment. They can also be used as distributing devices at lower voltage side of packaged trans-former substations.

The switchgears are often employed at large and medium scale industrial facilities, hydrocar-bon field infrastructures, refineries, metallurgical complexes, municipal utility services etc.

Design

The low voltage switchgears are manu-factured as cabinets, drawer modules, blocks, boards, panels or as combined complexes with single or double sided access. There are hang-on and floor-standing options. Hang-on designs can be fixed at some posts, columns or vertical walls. Floor-standing modifications can have a base plate, adjustable supports or wheels. The base plate options are the mostly protected against foreign objects and an inadvertent access to con-ductive parts. Adjustable support options can be mounted on an uneven coverage whereas the wheeled designs can be moved wherever neces-sary.

Each type of switchgears is designed as follows:

• the block is a switchgear with internalequipment mounted on a frame, plate or any other kind of a base as high as 1200mm max. IP00

• the drawer module is a fully coveredswitchgear to be vertically hanged (on a column, wall etc.) as high as 1200mm max. IP31, IP41, IP54

• the panel is a switchgear with internalequipment mounted on functional racks and a plate as high as 1800 mm min. IP00

LV Switchgears

Functional Classification

LV S

wit

chge

ars



Rated voltage V upto 1000

Rated insulation voltage V 1000

Rated current of collector bus bar A upto 5000

Peak withstand current of busses kA 187

Mains frequency Hz 50/60

Protection as per ГОСТ 14254-96 upto IP 65

• the cabinet is a switchgear fully covered against any accessto conductive parts. There several variants of splitting to compartments from 1to 4b. It is possible to make some components as drawer modules. IP20, IP31, IP41, IP54

• the board is a switchgear consisting of several panels orcabinets. Open boards have IP00 protection. Closed boards have IP20, IP31, IP41, IP54 protection.

• the console is a switchgear containing control, alarm andmeasurement equipment. Can be serviced by an operator in standing or seated position. IP20, IP31, IP65.

A climatic modification and a location category are УХЛ 4 as per GOST 15150-69 for intrastate supplies and for export to mild climatic areas, O4 – for tropical countries.

Internal equipment lay-out is planned in accordance with project documentation of a customer.

All types of switchgears from basic and to the most complicated designs are first of all peculiar for a simple, easy, accessible and reliable installation as well as a protection against an inadvertent access to conductive parts.

System flexibility makes it possible to cope with any unforeseen circumstances concerning the project implementation including changes of an original engineering design. Any changes while in operation can be accomplished by replacing or adding new modules.

Our production facility is equipped with all cutting edge machinery to produce high quality skids. Buses are treated with ALFRA equipment.

High quality is achieved owing to modern production techniques, qualified personnel, just-in-time training, state-of-the-art equipment and to regular tests.

92 93

Designation

The systems are intended for remote, automatic and local control of air cooling units with a variable frequency drive and electric drives for louvres, maintenance of a product outlet temperature to secure and control production processes.

The system makes it possible:

• toextendtheoperationperiodbetweenrepairsbyoptimizing the number of motors in operation

• toexpandthegaspipecapacitybymaintainingthepreset temperature mode

• toreducetheelectricityconsumptionby25-40%by variable frequency control of motors

• to increase the service life of electric motorsand mechanisms by a smooth start-up and programmable motor control

• to prevent lower parts of a heat exchanger fromfreezing by a reverse mode of electric fans

• to exclude emergency situations by initiatingwarning signals when approaching critical values (vibration increase, loss of phase - power supply side and motor side)

• toinformanoperatoraboutthesystemparameters,condition of the constituents by displaying the data on a computer screen

• toprovide remotecontrolof thesystem from theoperator’s computer.

Air Cooler Automatic Control System

Air cooler system for the high pressure gas compressor (Vankorskoye field, stage 3)

Characteristics:

• 2coolingstages

• 4aircoolers

• 3electricmotorsperonecooler

• 1 variable frequency drive per a 3-motorgroup, cascade control

• power supply equipment is installed in twocabinets – 2200 x 3200 x 600 mm

• 2variablefrequencydrivesper1coolingstage

• installedpower360kW

Air

Coo

ler

Aut

omat

ic C

ontr

ol S

yste

m

94 95

Contactless Torque Meter For 2-32 MW Gas Compressors

Designation

Intended to measure a torque for real-time power determination at industrial gas compressor transmission shafts. To be used as part of gas compressors and plants producing gas transfer equipment.

Complete cycle of works is available: engineering, calibration, alignment, commissioning and warranty servicing.

Features and main characteristics:

• operation under severe conditions of high temperature andfugitive oil

• 1ExibIIBT4design

• easytoinstall

• increasedclearancebetweenarotorandastator(upto10mm)

• torquemeasurementerroris0.5%

• maximumrotationfrequencyofarotoris15000rpm

• canbe integratedtoanupper levelsystemviaMODBUSRTUprotocol

• outputsignals:current4-20mA,RS-232/485

• timebetweenoverhaul–25000hours

Con

tact

less

Tor

que

Met

er F

or 2

-32

MW

Gas

Com

pres

sors

Contactless Torque Meter

Designation

Designed to measure a torque and a power of rotating shafts in machines and mechanisms i.e. motors, reduction gears, vehicles, etc. The operating principle is strain-gauge to attain high accuracy and efficiency.

The design features of each unit are customer definable considering the measurement range, coupling dimensions, rotation frequency, working fluid, temperature, etc.

Application

• testfacilitiesofaviationandspaceengineering;

• shipbuildingandautomobileindustries;

• machinetoolbuildingindustry;

• testingofengines,pumpsandreductiongears;

• testing of machines and mechanisms at machine-buildingenterprises.

Features and main characteristics:

• possibility of operation under severe conditions (extremetemperature, oil operating environment)

• resultsdisplayinphysicalunits

• possibilityofvariablesignalmeasurementwithasamplingfrequencyof up to 16 kHz

• customerdesignintegration

• class1ExibIIBT4protection

• increasedclearancebetweenarotorandastator(to10mm)

• torquemeasurementerroris0.2%-0.5%

• max.rotationfrequencyforarotoris50,000rpm

• operatingtemperaturerange:-40°Cto+105°C

• outputsignals:current4-20mA,RS-232/485

• continuousrunningtimeisnotlimited.

96 97

Lightning Protector M-200

Active type lightning protector based on an upward leader initiation.

KOSMOS-NEFT-GAS proudly presents a proprietary design of an active type lightning protector to screen welfare and industrial facilities against direct damaging by a lightning discharge.

An internal electronic block which is a generator is charged with thunderstorm electric field energy and initiates an upward leader in advance of all other leaders of the facility being protected.

Quality control

Each M-200 lightning protector undergoes a series of high voltage tests in order to verify proper generator operation and electric insulation reliability.

M-200 technical characteristics

Three-dimensional configuring of the M-200 coverage area guarantees an effective protection of various structures and buildings.

Ligh

tnin

g P

rote

ctor

M-2

00

Advantages of M-200

Wider protection coverage as compared to conventional lightning rods and active protectors by other producers. Our equipment does not require any external power sources for functioning. Purely Russian invention. Attractive pricing.

Design of M-200

1 – upper rods are actually lightning receivers and serve for generator charging and upward leader initiation

2 – external dischargers protect the electronic block from being damaged by lightning current

3 – sealed dielectric housing with ribbed outer surface contains a device to generate high voltage on the receiving rod in advance of a lightning discharge

4 – base flange for support and grounding system connection

The table shows protected area radii depending on the device installation elevation and protection reliability.

where hх - height of the protected facility

Rх - protection area radius at Hx elevation, m

h - height up to the tip of the lightning protector

hm

- height of the lightning protector

Ro - protection area radius at zero ground, m

K - trial coefficient

Level 1, protection probability Р=0,995; К=0,01



The facility protection coverage is to be calculated by the formulae:

h,m Protection radius RO

, m

Level 1 Level 2 Level 3

3 17 24 31

4 20 28 36

6 24 34 44

8 28 40 51

10 31 44 57

15 38 54 70

20 44 63 81

30 54 77 100

40 63 89 115

60 77 109 141

80 89 126 163

98 99

Advantages of the air turbine unit as compared to gas turbine units with regenerative cycle:

1. Serviceability with any kind of fuel without special treatment

2. High reliability and a long life term (due to zero skew, over temperature, turbine corrosion and blackening absence)

3. Low hazardous waste emissions (owing to the specific burning process typical for heating furnaces and boiler houses)

4. Broader application sphere

•lowpressure(from0,001MPa)naturalgas and oil associated gas directly at the field

•syngas,endgasandsourgasatrefineries, liquefied gas plants

•liquidfuel(dieseloil,furnaceoil, black oil and liquid hydrocarbon wastes)

Air turbine diagram Typical air turbine arrangementТВУ

INNOVATION: Air Turbine Unit

AIR TURBINE UNIT

As an electric generator drive

•powersupplyatoiland gas fields and while disposing of different gases at refineries

As an injector drive

•pressureboostingatdepleted gas fields

•oilassociatedgaspressureboosting while transporting to a refinery

As an air compressor

•heatingoffacilitiesandequipment

•drivefordifferentdevices

•Dryingofdifferentmedia

As a sour gas disposal unit

•sodiumsulfateandbisulfate synthesis

DesignationAlternative sources are intended to energize well control

systems located far away from centralized mains or when such power line connection is economically unsound.

Equipment composition

Alternative sources include generators, transforming and accumulating equipment as well as control and power distribution equipment.

Gasoline, diesel, gas and turbine generators are used along with the devices based on a gas line pressure differential, direct heat conversion into electric power, and also solar and wind generators.

The power produced by the generators is transformed with a controller based on a certain algorithm and charges an accumulator battery.

The accumulated energy is supplied as a direct current to the loads either directly or inverted to a sinusoidal alternating current.

In order to raise the electric reliability a system usually includes several types of generators to form a hybrid installation. Thus, wind and solar generators are redundant with an accumulator battery and an additional gasoline or diesel generator.

The most attractive are the installations with turbine generators operating on a produced gas. Below are the advantages of such designs:

• independent on fuel supplies (the fuel is always availablelocally)

• independentonweatherconditions

• advanced reliability and design simplicity (there is only onerotating part – a rotor)

• easytoreplaceandrepair(nolubricationsystem)

• sufficientlyeffective,lessweightcomparedtoaunitofpower

• lesspricecomparedtoaunitofpower

• lessexpensivetransportationandinstallationworks.

Constant expenses are for a transformation and control equipment and for an accumulator battery.

The power of the hybrid electric station depends on application conditions, reliability level and installed power of loads that amounts from 300 – 500 W to 10 – 20 KW.

Alternative Power Sources

Alt

erna

tive

Pow

er S

ourc

es

100 101

A security infrastructure at Russian highways is essential due to lack of mobile phone coverage on the most territory of Siberian and Far East road network.

To solve this problem KOSMOS-NEFT-GAS in the collaboration with the ARBUZ company from Magadan have designed stationary posts of emergency communication and heating.

The posts are to be installed in a close proximity to a roadway in the most dangerous areas according to the data provided by the Ministry of roads, transportation and communication.

The post of emergency communication comprises:

•acommunicationsystem

•apowersupplysystem

•avideosurveillancesystem

•asecuritysystem

•aheatingsystem

The post is equipped with a communication system to call an operator and a power supply system to energize other systems. It also contains video cameras and loud speakers.

Due to our posts a person in need can call a public safety answering point that is the Federal Rescue Service. The operator on duty is obliged to take all measures to render help. If necessary the operator can open access into a heated room inside the post.

Local system of mobile communications

A mobile phone coverage is available within 200 metres. Any network subscriber can call special services with a personal phone (3G/UMTS) or dial a federal emergency response number 112.

Post

s of e

mer

genc

y co

mm

unic

atio

n an

d he

atin

g

Posts of emergency communication and heating

In case when there is no possibility to use a mobile phone (broken, low battery, 3G not supported) it is possible to call an operator by means of an emergency call button. The button is intended for communications with a public safety answering point that is the Federal Rescue Service or “emer-gency dial 112”. Just push the button to start your conversation via a two-way video conference with an operator on duty.

If necessary the operator can open access into a heated room inside.

The room is equipped with a stand-alone heater and a thermostat to maintain a constant warm temperature. It also contains lighting, operator communication and video surveillance as well as a universal phone charger. There is a first aid kit: a medicine box, warn clothes, a tank with water and food.

A person in need can stay in the heated room until a rescue team arrives. There is enough fuel to keep the room heated for 12 hours. An energy reserve

of 248 KW∙h (can be extended upto 464 KW∙h)can supply power to all main systems of the station for many months.

The data transfer system receives and transfers data (including video surveillance) in real time.

The video surveillance system consists of cameras for outer and inner view surveillance and for video calls.

The monitoring system shows current states of all subsystems and sensors.

Companies collaborated in the project: ARBUZ (Magadan), KOSMOS-NEFT-GAS (Voronezh), EUROMOBILE (Saint Petersburg), STABCOM ENERGY (Moscow).

The first self-contained post of emergency communication has been commissioned in Russia at the 311 km of the

Kolyma federal highway.

Emergency Voice System

102 103

Designation

Remoteness of controlled facilities and decentralization of automatic control, fiscal accounting, security and video surveillance systems is a power supply bottlenecking due to the absence of unified industrial power sources. For example, 10-150W output in most cases is sufficient, therefore designing, manufacturing and servicing of various electrical power transmission lines is economically unviable.

KOSMOS-NEFT-GAS has developed a stand-alone power supply complex for different power demands.

The complex is designed for uninterrupted power supply by way of direct decompounding of methyl hydroxide and solar energy conversion.

For permanent installation the equipment is fixed in a solid base. For temporary installation it can mounted on a sufficiently stable ground. The complex consists of a thermobox (HхWхD – 630х1110х800 mm) with all the main equipment. Solar panels can be mounted additionally on dedicated supports (HхWхD – 2400х1100х1510 mm).

The peculiar features are stealthiness, low noise and no emissions as the side products are a carbon dioxide and aqueous vapor.

Minimum maintenance is required – just once per every 4-6 months (relevant when solar panels are installed, duration of autonomous operation is based on customer’s demands). Operation parameters are controlled remotely.

The complex has modular structure and can be modified based on particular application requirements and preferences of a customer.

Can be used as a main and back-up power source for:

• radiocommunicationandmonitoringsystems;

• equipmentforgeodeticandcartographicworks;

• portable equipment of travelling repair crews (local lighting forrepair sites, radio communication);

• securityandfireannunciationsystems,videosurveillance;

• remoteemergencycommunicationstations.

.

Stand-alone power supply complex

Power supply complexes with solar panels and a wind generator for a stand-alone

wellhead control panel.

The complex also includes a double channel wattmeter recorder that is another invention of KNG experts.

That product is designed to measure AC parameters such as voltage and power via two independent channels with galvanic separation and can be integrated into an upper level control system. The wattmeter recorder has following functions:

• measurementofvoltage,currentandpowerofeachsource;

• measurementofampere-hoursandwatt-hoursforeachchannel;

• measurementoftime;

• operationviaRS-485 interfacewithMODBUSprotocol for remotereading of measurement results and control;

• canbeintegratedintoanupperlevelcontrolsystem.

The device can operate indoors at 0-50°С and a relative humidity of 80%.

The power consumption is 12-24 V DC.

Measurement limits and errorsMax measured voltage, V..................................................50;Max measured current, А..................................................15;Fundamental measurement error, %, not more than............0,5.



Output power W 100

Max allowed peak output (30 seconds) W upto 5000*

Current DC

Output voltage V 12/24*

Allowable deviation of output voltage % -10 …+20

Short circuit protection yes

Overload protection yes

Fuel methyl hydroxide

Rated fuel consumption lper1KW∙h 0,9

Time to full rated capacity h 0,5

Output power of solar batteries W 600

Fuel cell efficiency % 40

Ingress protection IP54

Ambient temperature °C from -60 to +40

Relative humidity % 80

Ambient pressure kPa (mm of mercury) 84 – 107 (630 – 800)

Recommended operation elevation, upto м 1500

Data transfer interfaces GSM, LAN, RS-232/485, FDDI*

*Depending on a design and customer’s requirements.

Stan

d-al

one

pow

er su

pply

com

plex

104 105

Wea

ther

proo

f Cab

inet

s for

var

ious

equ

ipm

ent

106 107

Thermo cabinet – IP54 burglar-proof enclosure. Thermal insulation properties of the cabinet have been successfully proof tested in an environmental chamber and at customers’ sites.

Weatherproof Cabinets for various equipment



Overall dimensions (HxWxD) мм 1810х780х980

Weight kg 220

Ingress protection IP54

Operating temperature range °С from minus 60 to plus 50

Flammability classification Г1

Weight Composite panels with an integrated load bearing structure

The cabinet is equipped with eye bolts to facilitate transportation and with a base plate for secure installation. The base plate can be modified for installation at an unprepared ground. Inside the cabinet there is a standard structure with racks and shelves for equipment. It can be additionally fitted with heating and ventilation. A ventilation grid can be covered against wind and rain.

Thermobox – the functionality is similar to full scale designs and it can be installed without weight lifting machinery. 2-4 people can easily move it (depending on how heavy is the equipment inside).

There are expending nuts in the exterior walls to fix various attachments (antennas, solar panels, light stands). Inside there are shelves and trays for customer’s equipment.

The design can be customized.



Overall dimensions (HxWxD) mm 600х1100х800

Weight kg 60

Ingress protection IP54/55

Operating temperature range °С from minus 60 to plus 50

Flammability classification Г1

Housing material Composite panels with an integrated load bearing structure

Inde

pend

ent P

ower

Sup

ply

Sour

ces

108 109

Independent sources of power can be an ideal solution for remote facilities without any access to centralized power transmission lines and inability to use diesel/petrol powered generators.

Distinctive features of independent power supply sources mutually pro-duced by the KOSMOS-NEFT-GAS and NAUKA NPO are:

• operationalflexibility;

• multifuelcapability;

• long-termautonomousoperation;

• quickinstallationandmaintenance.

Climatic modification is УХЛ category 1 as per Russian GOST 15150 69. The design conforms to requirements of GOST 29328-92 and VRD39-1.10-071-2003.

A free piston Stirling engine is a thermal machine based on a supply of external heat to the heated area and removal of internal heat from the cooling area. The engine is fully unattended during the entire service life.

It does not require any lubrication system. The unit is sealed and damp-proof and is not intended for disassembling within the service life. The engine is heated from an external burner that uses either an LP gas, or liquid fuels or wood chips.

The service life rate does not depend on the load.

Application options:

• self-contained power supply to communication and radio detection com-plexes;

• supportofequipmentandlivingquartersinhard-to-reachareas;

• back-upandemergencypowersupplyforfacilitieswithstrictrequirementsrelated to uninterrupted failure-free operation.

The most space saving Stirling based power source is Evogress 1.0. Its basic advantages as compared to other engines of similar capacity are a low noise level and less toxic exhaust as well as no need of regular maintenance. The fuel can be supplied from a standard bottle. Heat is a side product of the engine.

Independent Power Supply Sources Solutions based on free piston engines (Stirling engines)



ISO normalized active terminal power W 1000

Current frequency Hz 50

Current AC

Terminal voltage V 220

Rated power output А 4,5

Efficiency 20 (±2)%

Fuel natural gas

Ambient temperature during operation °С +6 … +70

Automation degree 4

Max noise load when in rated power mode at a distance of 10 m dB (A) 50

Overall dimensions (HxWxD) mm 1000x1000x1000

Weight kg 90

Evogress 6.0 type starts a line of generators over 1 KW. This product has

been successfully prove field tested and accepted by the GAZPROM commission.

The entire product line of independent power supply sources has been granted

with conformance certificates of GOST R, GAZPROMCERT and a voluntary

certificate of the industrial safety «CertPromBezopasnost». Owing to horizontal

arrangement the product can be transported with all kinds of vehicles

without exceeding allowable dimension limits.



Min rated electric power KW 6 x 1,0

Effective electric power KW 5,128

Current DC

Output current А 107

Output voltage V 48

Automation degree 4

Unattended operation h 8760

Max meantime between failures h 10000

Max average overhaul life h 100000

Max efficiency related to rated power in ISO conditions % 20

Fuel flow rate m3/hour 2,83

Specific fuel consumption m3/KWh 0,57

Max container weight with equipment кг 2000

Container dimensions LxWxH, mm 5500х2300х2700

Fuel type Natural gas

110 111

The independent power supply source type

Evogress HG is capable to use solid fuels (wood

chips, pellets etc.). Evogress HG is indispensable

when liquid and gas fuels are hard to be brought to

hard-to-reach areas.

Independent Power Supply Sources Solutions based on free piston engines (Stirling engines)

Inde

pend

ent P

ower

Sup

ply

Sour

ces



Electric power W from 1000

Thermal power W from 5000

Current AC

Current frequency Hz 50

Terminal voltage V 220

Overall efficiency % upto 30

Electrical efficiency % upto 90

Fuel type solid fuel

112

P R O D U C TC A T A L O G U E

Dear top managers and businessmen, please, accept our product catalogue for your information about the activities of the Financial and Industrial Company KOSMOS-NEFT-GAS.

We truly believe that our products will attract your attention. Should you require any additional information on the products we make or services we render, or should you decide to place an order, please, do not hesitate to contact our foreign affairs team, who will assist you in getting in touch with the appropriate departments.

Best regards,

Alexander P. Shevtsov

Director General

KOSMOS-NEFT-GAS Group of Companies

Contact information

180, 9 Yanvaria Str., Voronezh 394019, Russian FederationPhone: +7 473 247-91-00, fax: +7 473 247-91-07

E-mail: [email protected] Affairs Department: +7 473 210 69 20

E-mail: [email protected]: www.kng.ru

PRODUCT CATALOGUE · 2019-06-21 · 9001:2008. In 2008 we were the first company to obtain...

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Transcript of PRODUCT CATALOGUE · 2019-06-21 · 9001:2008. In 2008 we were the first company to obtain...