future growth fgp · 1 modular substation was fabricated by skema llp in kazakhstan. performance...

KAZAKHSTAN

Caspian Sea

Uzbekistan

Kyrgyzstan

DISCOVERED IN 1979, TENGIZ IS ONE OF THE WORLD’S DEEPEST DEVELOPED SUPER GIANT OILFIELDS. THE FUTURE

GROWTH PROJECT (FGP), INTEGRATED WITH THE WELLHEAD PRESSURE MANAGEMENT PROJECT (WPMP), ARE EXE-

CUTED SIMULTANEOUSLY TO EXPAND TENGIZ PRODUCTION AND MAINTAIN FULL PRODUCTION RATES OF THE EXIST-

ING TENGIZ FACILITIES. THE FGP PLANTS WILL NOT PRODUCE SULFUR. THE NATURAL GAS CONTAINING HYDROGEN

SULPHIDE WILL BE RE-INJECTED INTO THE RESERVOIR TO MAINTAIN RESERVOIR PRESSURE. THE EXPANSION IS DE-

SIGNED AND CONSTRUCTED TO OPERATE WITH THE LATEST TECHNOLOGY TO REDUCE AIR EMISSIONS.

FUTURE GROWTH PROJECT (FGP) / KAZAKHSTAN ONSHORE

“This was a technically challenging order. As a result Skema worked very collaboratively with our engineering and management team to

come to successful solutions.”

Project Manager

EPC CONTRACTOR: KPJV / A JV BETWEEN: FLUOR / WORLEY PARSONS / JSC KING AND LLP KGNTEND USER: TENGIZCHEVROIL / A CONSORTIUM OF: CHEVRON / EXXONMOBIL / KAZMUNAYGAS / LUKARKO

ENGINEERING

The substations supplied for the FGP/

WPMP project are one level steel

structures installed above a concrete

foundation. The main structure con-

sists of transverse frames connected

by floor beams, wall corrugated plates

and floor plates. The main structure is

completed with longitudinal beams

connecting the bottom of the main

columns. The structures and machin-

ery are designed to withstand the

seismic design loads and to meet the

general seismic requirements, in ac-

cordance with the SiD (Safety in De-

sign) requirements. All analyses were

carried out using Semi-probabilistic

method at Limit states (LSD), while all

structures were analyzed using FEM

method bend on the package 3D

model, considering the operation con-

figuration and the lifting phase.

For seismic analysis static analysis

was carried out. The lifting was from

top of the substation.

A 3D separate model was generated

for each module in a right handed or-

thogonal Cartesian coordinate sys-

tem. The structural models of the

modules were representative of the

actual structural components and in-

cluded all primary framing members,

namely columns, f loor beams and

floor plates.

FABRICATION IN ITALY

The modular substations fabricated in

Italy were tested at Skema’s yard fa-

cilities, then disassembled in modules

and transported by road to Tengiz, to

be reassembled locally.

The supply included 10 Container-

ized complete transformer 10/0.4 kV

substations for the Contractors’ Com-

pound / Early Works, equipped with:

> 10 kV Gas Insulated Switchgear

(6 sections)

> 10 kV Ring Main units (24 sections)

> Intelligent PMCCs

(66 sections, 154 drawers)

> Distribution Boards (68 sections)

> 220 VDC system

> 220 VDC Ni-Cd battery rack

> 10/0.4 kV cast resin Transformers

> Lighting and electrical system

> HVAC system

> Fire and gas system

2 Containerized 35/10 kV packaged

substations were fabricated for New

Camp 9/A, and were equipped with:


(21 sections)


(26 sections)

> 10 kV Disconnector Switches

(4 sections)


> 220 VDC system


> 10/0.4 kV – 750 kVA cast resin

Transformers

> On Load Tap Changer (OLTC) panel

> Patch panel

> Badge reader access door


> HVAC system


The equipment was pre-assembled

and base plated mounted to the maxi-

mum extent including piping, supports,

instruments, wiring, junction boxes.

“I would like to thank you and your team for producing a quality product which will serve TCO for many years. I appreciate your effort, patience and understanding in working with us to achieve this significant milestone of

signing off the substations for T9A and Orken Village to the required standard

and to the agreed schedule.”

Lead Project Engineer

FABRICATION IN KAZAKHSTAN

Skema LLP was awarded the local fab-

rication of 1 Containerized 10 kV pack-

aged substation for the Construction

Compound. The substation included:


(15 sections)


> 220 VDC system


> Cast resin Transformers 35/0.4 kV


> HVAC system


The equipment was pre-assembled

and base plated mounted to the maxi-

mum extent including piping, supports,

instruments, wiring, junction boxes.

The modular substation fabricated

in Atyrau was tested at the fabrica-

tion yard facilities, then disassembled

in modules and transported by road

to Tengiz, to be reassembled locally.

For the modular substations fabricated

for the FGP/WPMP, Skema supplied the

following services: preservation, pro-

tection and storage at the fabrication

yard; disassembly in modules; pack-

aging, preservation and protection for

sea and land transport; winterization

for shipment and storage; load out.

Skema was in charge of the sizing, detailed design, engi-

neering, project management, scheduling, procurement,

fabrication, painting, inspection, non-destructive exam-

ination, shop testing, expediting, QA/HSE management,

documentation and preservation of 13 Modular Substa-

tions. The fabrication, multidisciplinary installation ac-

tivities (architectural, mechanical, E&I, HVAC, etc.), test-

ing and pre-commissioning of 12 modular substations

were carried out at Skema’s yard in Ravenna, Italy, while

1 modular substation was fabricated by Skema LLP in

Kazakhstan. Performance was according to IEC/GOST

standards and PUE ROK.

SOLUTIONS DELIVERED

13 MODULAR SUBSTATIONS

MV 10/35 KV SWITCHGEAR (68 COLUMNS)

MV 10 KV RING MAIN UNITS (24 COLUMNS)

INTELLIGENT POWER MOTOR CONTROL CENTERS (66 COLUMNS, 154 DRAWERS)

DISTRIBUTION BOARDS (104 COLUMNS)

EPC CONTRACTOR: KPJV / A JV BETWEEN: FLUOR / WORLEY PARSONS / JSC KING AND LLP KGNTEND USER: TENGIZCHEVROIL / A CONSORTIUM OF: CHEVRON / EXXONMOBIL / KAZMUNAYGAS / LUKARKO

future growth fgp · 1 modular substation was fabricated by skema llp in kazakhstan. performance...

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