Thermo Design signed a contract with ZAO Stimul (an independent joint-stock company and major share holder: of Gazprom) to expand the existing facilities of an Oil & Gas Processing Plant near the Orenburg Region of Russia. The scope of the project included the design and supply of equipment to upgrade the existing train, and supply an additional train, each with the ability to process reservoir fluids to a maximum of 500,000 tonnes/year in product crude oil.  In addition, the design services for the future phases of the plant expansion were to be completed, including one more processing train to bring the production of the plant to 1,500,000 tonnes/year.

The contract included the following Thermo Design supplied equipment and services:

• Design and supply of additional equipment for existing oil & gas processing train to improve quality of oil separation, dehydration and desalination.
• Design and supply of new water treatment facilities for existing and future trains.
• Design and supply of new oil & gas processing trains. 
• Design and supply of additional utility systems required for operation of new equipment.
• Design and supply of flare system required for operation of existing and new equipment.
• Registration of plant and equipment with Russian Authorities and Standards Agencies.
   

Plant Equipment Summary

Preliminary Separation

Feed Flow rate:    Liquid:  255 m3/hour at 16 barg
    Vapour:  71,140 m3/hour at 16 barg
Process Facilities:    Inlet Manifold, LP Separator
Inlet Manifold Capacity:    10 Inlet Tie-in Points
Separator Type:    3-Phase, Horizontal

Crude Dehydration / Desalination

Dehydration Technology:    Electrostatic
Process Facilities:    Crude Oil Dehydrator, Crude Oil Desalter, Crude Heater, Wash Water Pumps, Feed/Product Exchanger, Wash Water Exchanger
Dehydrator Type:    3-Phase, Horizontal Grid
Desalter Type:    3-Phase, Horizontal Grid
Crude Heating:    Indirect Fired Heater, 960 kW, Forced Draft

Gas Handling

LP Gas Compression:    740 kg/hour. Reciprocating Separable Compressor with Electric Motor, Single-Stage Gas Compression, Vertical Direct-drive Air Cooling, Lube Oil Auxiliary System.
HP Gas Compression:    30,000 kg/hour. Reciprocating Separable Compressor with Natural Gas Driven Engine, Single-Stage Gas Compression, Horizontal Belt-driven Air Cooling, Lube Oil Auxiliary System.
Compressor Control:    PLC's integrated into plant network.

Heat Medium System

Heat Medium:    50% Weight Glycol at 95°C.
Process Facilities:    Heat Medium Heater, Heat Medium Drain Drum with Pumps, Heat Medium Circulation Pumps.
Heat Medium Heating:    Direct Fired Heater, 1484 kW, Forced Draft

Flare & Drainage Systems

HP Flare Type:    Air Assisted
HP Flare Capacity:    85105 kg/hr (120% of Maximum Flow)
LP Flare Type:    Pipe Tip
LP Flare Capacity:    5170 kg/hr (120% of Maximum Flow)
Flare Design Criteria:    Stack Velocity < 0.5 Mach
Ground Level Radiation Level < 6.3 kW/m2
Smokeless Combustion up to 25% Design Capacity
Auxiliary Flare Equipment:    HP Flare Air Blowers, HP Flare Knock-out Drum, LP Flare Knock-out Drum, 2 HP Flare Pilot Burners and 2 LP Flare Pilot Burners with Flame Front Ignition and Automatic Re-Light, Smoke Monitoring System.
Plant Drainage Systems:    Full Plant Flare and Process Drainage Requirements.
Plant Drainage Equipment:    HP Flare Knock-out Drain Drum with Pumps, LP Flare Knock-out Drain Drum with Pumps, Hydrocarbon Drain Drum with Pumps, Water Drain Drum with Pumps.

Produced Water Treatment Systems

Capacity:    3 Trains at 190 m3/hr.
Controlled Properties:    Dissolved Oxygen, Oil, Suspended Solids.
Injected Chemicals:    Demulsifier, Caustic, Aluminum Sulphate (Coagulant), Sodium Hydroxide (Caustic), Sodium Sulfite
Major Equipment:    Degasifier Tank, Produced Water Booster Pumps, CPI/IGF Separators, Sludge Pumps, Coagulation Tank, Flocculation Tank, Sand Filters, Treated Water Transfer Tank, Treated Water Pumps, Service Water Pumps, Filter Backwash Water Settling Tank, Treated Water Storage Tank, Treated Water Booster Pumps Pumps, Chemical Tanks, Chemical Injection Pumps and Mixers.

Crude Oil Storage

Capacity:    4 Surge Drums at 200 m3 each.
Major Equipment:    Crude Oil Surge Drums, Crude Oil Booster Pumps, Crude Oil Pipeline Pumps.

Instrument Air Package

Capacity:    2 Compressors at 5.2 Nm3/min each.
Major Equipment:    Instrument Air Compressors, Air Filters, Air Dryers, Dry Air Receiver.

Fresh Water Treatment System

Capacity:    22.5 m3/hr.
Controlled Property:    Iron
Major Equipment:    Aeration & Storage Tank, Storage Pumps, Sand Filters, Backwash Tank, Backwash Pumps, Fresh Water Storage Tank, Fresh Water Pumps, Chemical Tanks, Chemical Injection Pumps and Mixers.