2008 Moscow Carbon Market Forum Moscow, April 28 & 29, 2008 PROJECTS FOR REDUCTION OF REPUGNANT SUBSTANCE EMISSIONS, AND FOR REDUCTION OF ANY LOSSES & NON-PRODUCTIVE EXPENSES RELATED TO NATURAL GAS TRANSPORTATION BY CROSS-COUNTRY GAS PIPELINES By Mssrs Ye. Gavrikov, V. Zhabin, A. Zhukov, D. Kosarev, K. Leschukov, G. Melnikov, Ye. Shtin & N. Schoukin Группа Компаний «МЕЛАКС»
Part 1 USE OF THE CONTROLLABLE ELECTRIC GAS -COMPRESSOR PLANTS (EGCPs) C/W A VOITH TURBO HYDROCOUPLE AT THE GAS INDUSTRY FACILITIES FOR REDUCING THE POWER CONSUMPTION LEVELS AND THE REPUGNANT SUBSTANCE EMISSIONS Группа Компаний «МЕЛАКС»
Introducing a Voith Turbo Hydrocouple at the Cheboksary Compressor Station of the Volgo. Trans. Gas LLC Группа Компаний «МЕЛАКС»
Introducing a Voith Turbo Hydrocouple at the Cheboksary Compressor Station of the Volgo. Trans. Gas LLC EGCP automatic control system from a Russian manufacturer (Systema. Service PF) has been used Oil coolers from a Russian manufacturer (Gas. Kholod. Technika OJSC) have been used Группа Компаний «МЕЛАКС»
Controllable EGCP vs. a Gas-Turbine Plant (GTP) EGCP operation: • EGCP c/w a Voith hydrocouple - Drive parameter stability · Cheap night-time tariff option · High reliability - 99. 9% · Fast and 100% reliable start · Long service life · Minimum costs on maintenance & spare parts Группа Компаний «МЕЛАКС» GTP operation: • Capacity variation subject to air temperature and unit running time · Gas consumption to meet the on-site needs · Reliability of up to 97% · 95% reliable start · Resource of up to 100, 000 h · Expensive preventive repairs & spare parts
Controllable EGCP vs. a Gas-Turbine Plant (GTP) Indicator Power station of a combined-cycle plant Gas compressor station c/w a GTP 52 to 56% 28 to 35% Electric-power transmission efficiency factor 99 % - Engine+hydrocouple efficiency factor 93 % - Gas-compressor unit (GCU) drive efficiency factor 48 to 52% 28 to 35% СО 2 emission g/k. W-h 480 700 Capacity output efficiency factor Группа Компаний «МЕЛАКС»
Why are the controllable EGCPs being elaborated? • Availability/Fast start • Durability • Reliability • Lower cost • Lower repair & maintenance costs • Good environmental properties • Lower noise levels Группа Компаний «МЕЛАКС»
EGCP Advantages vs. a GTP • Simplicity • Reliability/Availability • Maintenance using the onsite resources • Lower price (installation included) • Compactability Группа Компаний «МЕЛАКС»
US Gas-Transportation System Profile Natural gas consumption in the USA will grow from 625 billion m 3 per annum in 2008 to 850 billion m 3 per annum by 2015 and to 1, 000 billion m 3 per annum by 2020 The majority of new power-station electricity-generating units have been the gas turbines that would require more and more gas Due to an increase in the price of gas for on-site needs, an electric drive would become economically competitive Environmental legislation has required reducing any GHG emissions while operating the gas-compressor equipment Группа Компаний «МЕЛАКС»
Use of the Voith Hydrocouples for Gas Transportation in the USA Controllable EGCPs have been the main injector type employed at any new GCSs of the US crosscountry gas pipelines Over 30 Voith hydrocouples rated 6 up to 30 MW have been sold in the USA for the above use to the satisfaction of gas-transportation companies Comparison between the EGCPs c/w hydrocouples and the GTUs has become a standard FS section in the US gas industry Группа Компаний «МЕЛАКС»
Advantages of using a hydrocouple while operating an adjustable drive Группа Компаний «МЕЛАКС»
Part 2 DIAGNOSTICS AND RECOVERY OF HERMETICITY OF VALVING AT THE UKRTRANSGAS COMPANY FACILITIES FOR REDUCING ANY METHANE RELEASES INTO THE AIR Группа Компаний «МЕЛАКС»
ORGGASNEFTESERVICE CJSC (Consumables for maintaining any valving at the GTS facilities) • Consumables (coupling pastes & slushing compounds) and equipment (high-viscosity material injector) for maintaining any valving used at the Gas. Prom facilities. • 2000 – commencement of cooperation with the Gas. Prom OJSC. • Over 500 ton – current volume of deliveries at the Gas. Prom subsidiary enterprises. • The Gas. Prom letters have recommended the above materials for on-site use for valving maintenance. • The products have been provided with the operation permits, licenses & approvals (certificates, sanitary & epidemiologic conclusions etc. ). • The products have been patented and included into a register of the Gas. Prom materials to be used at cross-country gaspipeline facilities. Группа Компаний «МЕЛАКС»
ORGGASNEFTESERVICE CJSC (Diagnostics & recovery of valving hermeticity to reduce any methane releases) End-to-end maintenance shall include: • Valving condition conclusion c/w a recommendation for replacing any diagnosed equipment. • Development of regulatory documentation; • 2006 – works at the Gas. Prom • Valving condition diagnostics subsidiary enterprises carried out. in the part of valve hermeticity; • 2006 – Org. Gas. Nefte. Service CJSC • Valving service maintenance; admitted to the diagnostics & maintenance of the Gas. Prom gas • Recovery of valving transportation facilities. hermeticity using any in-house technologies & consumables; and Группа Компаний «МЕЛАКС»
ORGGASNEFTESERVICE CJSC (Diagnostics & recovery of valving hermeticity to reduce any methane releases) Valving end-to-end maintenance shall include: • Review, processing & expertise of a package of regulatory & engineering documentation; • Visual and measurement control of the crucial components; • Drive performability monitoring; Группа Компаний «МЕЛАКС» • Valve hermeticity monitoring; • Shell metal & welded joint condition monitoring using any non-destructive methods (if necessary); and • Technical condition evaluation (reports on safe operation resources, replacement, repair, removal of any specific units etc. ). All works shall be carried out in accordance with the Gas. Prom standards.
DEMONSTRATION WORKS AT THE UKRTRANSGAS COMPANY FACILITIES Группа Компаний «МЕЛАКС»
PROGRAM FOR THE WORKS AT THE UKRTRANSGAS COMPANY FACILITIES • End-to-end maintenance has envisaged the valving hermeticity diagnostics & recovery using the materials and equipment from the Melax Group of Companies • The facilities have been the Du 300 to 1, 400 mm valving at a cross-country gas-pipeline and the Du 50 to 1, 000 mm valving at the compressor-station process piping • The site has been the gas-pipeline and the compressor station of the Cherkassy. Trans. Gas Company • Period – June 18, 2007 through June 27, 2007 • Anticipated outcomes – reduction of any GHG (methane) releases through the valving at the Ukr. Trans. Gas Company facilities Группа Компаний «МЕЛАКС»
QUANTITATIVE ASSESSMENT OF ANY GAS RELEASES THROUGH VALVING • Quantitative assessment of any gas releases has been made using the acoustic equipment for the surface & underground valving. • A dedicated software c/w a database on various valving types & sizes and on the entrance & exit pressure of transported products has been used for assessing any gas releases. • Valving hermeticity diagnostics has been made directly at the inspected equipment when in service. Группа Компаний «МЕЛАКС»
OUTCOMES OF QUANTITATIVE ASSESSMENT OF ANY GAS RELEASES THROUGH VALVINGA СО 2 -equiv. emissions, t/year Name Location Du (mm) 1 Borsig Т/А 3 -1 1, 000 1, 475. 73 2 Borsig Т/А 3 -2 1, 000 20. 01 Borsig Т/А 3 -6 Б 3, 000 5. 4 4 Grove Т/А 2 -5 100 2. 32 5 Grove Т/А 1 -5 100 3. 09 6 AZTPA Т/А 1 -1 1, 000 16. 22 7 AZTPA Т/А 2 -1 1, 000 16. 23 AZTPA Т/А 1 -2 1, 000 19. 32 AZTPA Т/А 1 -6 5, 000 9. 27 # Facility 3 8 9 CS-34 А CS-34 Б Группа Компаний «МЕЛАКС»
DIAGNOSTICS-BASED LIST OF VALVING TO BE COVERED BY HERMITICITY RECOVERY MEASURES # Facility 1 CS-34 А 2 3 Borsig Sigma CS-2 4 5 Name Sigma JSW JB-C 3, 667. 7 km KU Borsig Группа Компаний «МЕЛАКС» Location Du (mm) Т/А 3 -1 1, 000 Т/А 5 -2 700 Т/А 8 -2 700 CS junction point (valve #20) 1, 000 Valve #124 1, 200
VALVING HERMETICITY RECOVERY USING THE PROCESSES & MATERIALS FROM THE MELAX GROUP OF COMPANIES • Consumables for hermeticity recovery – slushing compounds and coupling pastes from the MELAX Group of Companies. • Equipment – high-viscosity material injector of in-house design. • Hermeticity recovery process based on an Individual Approach Principle (IAP) with the following equipment features taken into account: ü ü ü manufacturer, installation site, operation period, design features, the Company specialists’ operating experience and the statistical database on any similar previous works. Hermeticity recovery process shall include: 1. Washing any valve holes to a seal area with the use of a slushing compound (“purifier”); and 2. Pressure feeding of the coupling paste of a specific type or grade at the valving seal area. Группа Компаний «МЕЛАКС»
MAINTENANCE OUTCOMES AT THE UKRTRANSGAS COMPANY FACILITIES # Facility Location Т/А 3 -1 (Borsig) 1 Reduction of СО 2 equiv. emissions by 753. 9 t/year Circle-wise washing and filling of a valve Destruction of sealing elements. Replacement Т/А 8 -2 (Sigma) Circle-wise washing and filling of a valve Destruction of sealing elements. Replacement UP #20 (JSW JB-C 0) Circle-wise washing and filling of a valve Hermeticity recovered Washing of the valve holes Washing of previously coked holes Т/А 5 -2 (Sigma) CS-2 4 5 Outcomes (conclusions) Washing and filling of the coked lower part of a valve CS-34 А 2 3 Works performed 3, 667. 7 km KU #124 (Borsig) Группа Компаний «МЕЛАКС»
CONCLUSIONS ON THE WORKS PERFORMED AT THE UKRTRANSGAS COMPANY FACILITIES Halving hermeticity recovery process applied by the MELAX Group of Companies has proved efficient: – Performability of 16 out of 20 valving holes has been recovered. – Hermeticity of valve #20 of a junction point at Kirovograd Compressor Station (CS-2) has been recovered. – Registered СН 4 emission reductions at the CS-34 А (Т/А 3 -1) have been 35. 9 t/year, or 753. 9 t/year of СО 2 -equiv. Группа Компаний «МЕЛАКС»
CONCLUSIONS ON THE WORKS PERFORMED AT THE UKRTRANSGAS COMPANY FACILITIES • Use of the acoustic equipment by the specialists of the Org. Gas. Nefte. Service CJSC for the valving diagnostics has proved efficient while assessing the actual equipment conditions; • Reliability of the quantitative assessment of any gas releases made by the specialists of the MELAX Group of Companies has been confirmed by the parallel measurements by the UMG representatives; and • The processes, equipment & materials from the MELAX Group of Companies could be recommended for recovering the valving hermeticity and reducing any GHG emissions. Группа Компаний «МЕЛАКС»
VALVING END-TO-END MAINTENANCE AS A TOOL FOR REDUCING ANY GHG EMISSIONS THE PROPOSED END-TO-END MAINTENANCE WOULD ALLOW TO: • • Assess the actual valving conditions; Assess any methane releases through surface and underground valving; Assess any gas cross-flows within the GCU process piping to optimize the CS operation; Make a technical substantiation of the quantity of valving at the GTS facilities to be replaced; Remove or reduce any methane releases into the air; Optimize the GCU fuel gas consumption thus reducing any combustion product emissions into the air; and Establish a data base and accumulate any GHG (methane) emission reductions at the Client’s account under a relevant carbon unit register for further trading at the global market. Группа Компаний «МЕЛАКС»
TESTING OF THE HERMETICITY OF VALVE #20 AT THE KIROVOGRAD COMPRESSOR STATION (CS-2) FOLLOWING AN END-TO-END MAINTENANCE Группа Компаний «МЕЛАКС»
MEASUREMENT OF ANY GAS CROSS-FLOWS AT VALVE #20 OF THE KIROVOGRAD COMPRESSOR STATION (CS-2) Группа Компаний «МЕЛАКС»
Part 3 USE OF MOBILE COMPRESSOR STATIONS (MCSs) FOR GAS TRANSFER FROM THE GAS-PIPELINE SECTIONS UNDER REPAIR Группа Компаний «МЕЛАКС»
Basic Assumptions and Motivations Presently, prior to any works at the off-line gaspipeline sections, natural gas shall be vented into the air. • • According to the Gas. Prom environmental reporting, any methane emissions have been as follows: 1, 402. 1 thousand ton in 2004; 1, 434. 4 thousand ton in 2005; 1, 529. 9 thousand ton in 2006; and 8, 818 thousand ton in 2001 -2005. Группа Компаний «МЕЛАКС»
Experiments in the MCS Use In August & September of 2006, the Gas. Prom Trans. Gas Chaikovsky LLC performed the experimental works on a two-phase gas transfer at the Almaznoe gas-pipeline including: – Phase 1 – gas transfer from an off-line Urengoi-Petrovsk gas -pipeline section (1, 702 to 1, 727 km, Du 1, 420) to an Urengoi-Novopskov gas-pipeline; and – Phase 2 - gas transfer from an off-line Urengoi-Novopskov gas-pipeline (1, 704 to 1, 729 km, Du 1, 420) to an Urengoi-Petrovsk gas-pipeline. Группа Компаний «МЕЛАКС»
Hanover MCS Группа Компаний «МЕЛАКС»
General Layout for Connecting an MCS to a Cross-Country Gas-Pipeline Группа Компаний «МЕЛАКС»
Experimental Work Outcomes The amount of gas transfer from an off-line Urengoi. Petrovsk gas-pipeline section (1, 702 to 1, 727 km, Du of 1, 420) to an Urengoi-Novopskov gas-pipeline has been as follows: – 1, 885, 075 m 3 including 24, 753 m 3 of fuel gas. The amount of gas transfer from an off-line Urengoi. Novopskov gas-pipeline section (1, 704 to 1, 729 km, Du of 1, 420) to an Urengoi-Petrovsk gas-pipeline section has been as follows: – 2, 032, 361 m 3 including 34, 940 m 3 of fuel gas. Группа Компаний «МЕЛАКС»
Control Section Parameters According to the MCS Operational Requirements approved by Mr. B. Budzulyak, Director of the Gas. Prom Gas Transportation, Underground Storage & Use Department on June 29, 2005, the control section parameters shall be as follows: • • Length – 30 km; Du – 1, 420 mm; Pressure – 75 kgc/cm 2; and Gas transfer amount – 3, 054 thousand Nm 3. Группа Компаний «МЕЛАКС»
Conversion into СО 2 Equivalent 3, 054, 822 Nm 3 of natural gas could be transferred from a single control gas-pipeline section under repair. With 18 transfers per annum, the gas transfer amount would be 54. 987 million Nm 3, which would make 38, 490. 757 ton. A conversion would give 808, 305. 901 ton of СО 2 equivalent. Группа Компаний «МЕЛАКС»
Thank You For Your Time! 115054, Russia, Moscow, 4 th Monetchivovsky Pereulok (Lane), 1/6, Building 3, Telephone: +7(495) 789 -68 -73, +7 (495) 789 -68 -74, Fax: +7 (495) 951 -22 -51, www. gk-melaks. ru Группа Компаний «МЕЛАКС»
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