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SendCompressor station, Turkmenistan
Economical and eco-friendly plant for high-quality export gas
All over the world, the focus is placed on an efficient and eco-friendly utilisation of energy and improving the yield from existing oil and gas resources. Capital-intensive investments must be adapted to these new general conditions - just as they must for a large-scale industrial project in Turkmenistan. In collaboration with MAN TURBO AG we realised there a turnkey compressor station that converts low-pressure oil-associated gas and medium pressure mixed gas (natural gas mixed with oil-associated gas) into high-quality export gas. Fitted with the latest in technology, the plant now operates on an economic and eco-friendly level.
| Type of contract | EPC Engineering, Procurement, Construction and Commissioning |
| Client | State Concern Turkmenneft |
| Project | compressor plant capable of converting low-pressure oil-associated gas and medium pressure mixed gas into high-pressure export gas having pipeline quality |
| Plant site | Korpedje, Turkmenistan |
| Scope of services | engineering, procurement, erection and assembly, testing and examination, commissioning, start-up and performance testing of the process and ancillary facilities |
| Subsystems | e.g. gas compression trains (utilising turbo compressor units, dew point control plant (for adjusting the hydrocarbon and water dew points of the feed gas to the pipeline requirements), seawater desalination plant (producing plant and potable water), electric power plant (on the basis of a turbo generator), pipeline connecting the compressor plant with the Turkmenistan-to-Iran Gas Export Line, and other ancillary facilities. |
| Collaboration | integration of MAN TURBO AG as a consortium partner; delivery of six turbo compressor units (each including a heavy duty gas turbine with 9.5 MW ISO shaft power output) for compressing the gas and a turbo generator unit for generating 8 MW of electric power |
| Volume | approx. Euro 114 m |
| Completion | 2005 |
Enhanced quality, multiple benefits - The high-pressure crude oil produced in the Korpedje area contains large quantities of gaseous hydrocarbons (associated gas). Until recently, the oil-associated gas, after being freed from the oil under low pressure, was simply burned in dedicated flares, without any commercial utilisation.
State Concerne Turkmenneft, in the desire to enlarge the gas export into the northern part of Iran (through the existing Korpedje-KurtKui Transit Pipeline), decided to have Compressor Station Korpedje constructed. This station has been designed to handle both low-pressure oil-associated gas from the Korpedje area and medium pressure mixed gas from the SAZII Pipeline System.
In order to generate the required station outlet pressure of 76 bar, the oil-associated gas needs three consecutive compression stages (low-pressure, medium pressure and high pressure), whilst a single compression stage (high-pressure) is sufficient for the mixed gas. A total of six turbo compressor units manufactured by MAN TURBO carry out the compression work: one unit in the low-pressure stage, one unit in the medium-pressure stage and four units in the high-pressure stage. Heated due the compression process, the gas is being re-cooled at each compression stage in an air-cooled gas after cooler. The gases delivered to the compressor station do not meet the high quality requirements established by Turkmenneft for pipeline transportation. Conversion of the feed gases into the high-quality pipeline gas is being accomplished in a glycol-based, refrigerant-aided dewpoint control plant arranged between the medium and high pressure compression stage. The gas leaving the last compression is ready to be exported as a high-quality product through 1.8 km long pipeline that we built to join the Korpedje-KurtKui transit pipeline. The plant not only operates efficiently, but also fulfils all the conditions for cutting emissions. An extra benefit: the seawater desalination plant we developed generates a surplus of drinking water that is passed on to the region's communities. Following successful mechanical completion we supported our client in commissioning and managing the process and ancillary facilities by qualified personnel.
In order to generate the required station outlet pressure of 76 bar, the oil-associated gas needs three consecutive compression stages (low-pressure, medium pressure and high pressure), whilst a single compression stage (high-pressure) is sufficient for the mixed gas. A total of six turbo compressor units manufactured by MAN TURBO carry out the compression work: one unit in the low-pressure stage, one unit in the medium-pressure stage and four units in the high-pressure stage. Heated due the compression process, the gas is being re-cooled at each compression stage in an air-cooled gas after cooler. The gases delivered to the compressor station do not meet the high quality requirements established by Turkmenneft for pipeline transportation. Conversion of the feed gases into the high-quality pipeline gas is being accomplished in a glycol-based, refrigerant-aided dewpoint control plant arranged between the medium and high pressure compression stage. The gas leaving the last compression is ready to be exported as a high-quality product through 1.8 km long pipeline that we built to join the Korpedje-KurtKui transit pipeline. The plant not only operates efficiently, but also fulfils all the conditions for cutting emissions. An extra benefit: the seawater desalination plant we developed generates a surplus of drinking water that is passed on to the region's communities. Following successful mechanical completion we supported our client in commissioning and managing the process and ancillary facilities by qualified personnel.
- Throughput 1 billion Nm3/year of associated gas (3 bar supply pressure);
3 billion Nm3/year of mixed gas (35 bar supply pressure) - Pressure increase 3 bar to 76 bar (over three consecutive compression stages)
- Generator output 8 MW
- Seawater desalination 250 m3 of drinking water / day
- Plant area 50,000 m2
- Equipment 150 pieces
- Structural steel 300 t
- Hard tops 2,000 m2
- Roads 15,000 m2
- Concrete 4,000 t
- Building volume 25,000 m3
- Piping (total weight) 1,700 t
- Cable Length 30,000 m
- Site personnel 300 on average, max 650
- Total Manhours 2.8 million