Gazprom’s Science and Technology Prize

Development and implementation of a system for monitoring the technical condition and integrity of the linear part of Gazprom’s gas trunklines

A system for monitoring the technical condition and integrity of the linear part of gas trunklines which has been implemented at Gazprom is based on the use of:

• quantitative models and methods for the computational and analytical prediction of reliability and technology risk indicators;
• a hierarchical model of the criteria used for making decisions and drawing up the long-term programs of comprehensive overhauls at the linear part of gas trunklines, which is based on the spot computational analysis of the current values and expected dynamics of technical condition, reliability and technology risk indicators, as well as on the computational evaluation of the optimal time between facility overhauls.

The conceptual basis for the monitoring process is provided by the following regulatory documents, which have been developed and approved for the first time ever: “Gazprom policy in monitoring the technical condition and integrity of gas transmission and storage facilities” (Gazprom, 2010) and “Concept for monitoring the technical condition and integrity of the gas transmission system's facilities taking into account the relevant transmission targets” (Gazprom, 2011).

The regulatory framework of the system for monitoring the technical condition and integrity of the linear part of gas trunklines is represented by more than 20 standards and guidelines of Gazprom.

A GIS-based computational complex for gas trunklines has been created and implemented at Gazprom Transgaz Surgut, a gas transmission subsidiary of Gazprom. Said tool performs computational evaluation of the performance efficiency & repairability of the linear gas trunkline sections and operational technology risk, as well as determines the scope, methods and timeframes of diagnostics and repairs, evaluates the cost of the resulting technical measures planned, optimizes scenarios and draws up programs for the diagnostics and repairs of the linear part of gas trunklines.

O. Aksyutin (supervisor of the work, Gazprom), G. Milko-Butovsky, S. Ovcharov, V. Stolov (Gazprom VNIIGAZ), S. Alimov, O. Melyokhin, A. Pasechnikov (Gazprom), I. Ivanov, A. Rudenko (Gazprom Transgaz Surgut), M. Basin (Gaztranzit).

Nominating company: Gazprom VNIIGAZ (D. Lyugai).

Development and implementation of innovative algorithms and software for ranking the Unified Gas Supply System facilities by their systemic importance and a methodology for the assessment of the economic efficiency of adopting comprehensive safety systems at Gazprom’s facilities

The methodological approach (multi-criteria usefulness, risk) implemented for the newly proposed method for ranking Gazprom's facilities has made it possible to obtain new scientific results and substantiate the indicators, criteria, and variable descriptive parameters of the facilities subject to ranking, as well as methods for the evaluation of their systemic importance.

A hierarchical multi-level system of the indicative sub-criteria of systemic importance and a model for evaluating the impact of negative factors have been developed; a scale has been substantiated to be applied for measuring the hazards to the stable operation of Gazprom's facilities, taking into account the technological specifics and location region of the latter, as well as the structure and contents of the source data.

A unique adaptive algorithm for ranking various Gazprom's facilities by their systemic importance has been developed on the basis of the dynamic multi-criteria analysis of risks to the stable operation of the UGSS, as well as production and treatment facilities.

A methodological approach to cash flow modeling in projects for the implementation of comprehensive safety systems has been developed, the main requirements to the source data necessary for calculations have been determined, and the structure and component elements of damages inflicted by wrongful conduct and information security violations at Gazprom's facilities have been substantiated.

S. Khomyakov (supervisor of the work, Corporate Security Service of Gazprom), A. Bochkov, V. Lesnykh, Yu. Litvin, N. Zhigirev (NIIgazeconomika), I. Lubkova, R. Mavlyudov (Gazprom), Yu. Lavrukhin, O. Stenin (Corporate Security Service of Gazprom), E. Karpel.

Nominating company: NIIgazeconomika (N. Kislenko).

Improvement and implementation of import-substituting threaded fiberglass couplings for repairs at gas pipelines without stopping the transmission of gas

A safe and efficient technology for selective repairs at gas pipelines without stopping the transmission of gas has been developed and implemented with the use of high-strength threaded repair fiberglass couplings (RFC).

An entirely new force diagram of the RFC structure has been created on the basis of the experimental modeling of strength and lifetime characteristics of standard and improved couplings, which enables the most use of the strength properties of fiberglass by stretching it during the coupling installation process.

A regulatory framework has been developed with regard to the production technology and use of the RFC type threaded fiberglass couplings: the enterprise standard, technical specifications, and two Gazprom standards.

A. Kryukov (supervisor of the work), A. Filippov, Yu. Sharygin, V. Zorin (Gazprom Transgaz Ukhta), R. Alaberdin (Gazprom), V. Sharygin (Gazprom VNIIGAZ branch in the city of Ukhta), M. Danilov, A. Ponomarev (Noviye Technologii).

Nominating company: Gazprom Transgaz Ukhta (A. Gaivoronsky).

System for on-line geotechnical control and long-term field development planning designed for use by gas production enterprises

A system for geotechnical control and long-term field development planning has been developed; the system is unique for the Gazprom Group. It accumulates data obtained from the automated process control system for workstations (APCS W) and the industry-related geology & geophysics information system and is based on the use of certified simulators of reservoir and surface networks.

A new innovative automated algorithm, which is universal and suitable for use by all gas production enterprises and ensures the reduction of work performance time, has been created and implemented to obtain data on the optimal layout of the planned well stock when modeling the options for natural gas field development.

Domestic block-structured software has been developed and implemented for geotechnical control and long-term field development planning, which makes it possible to substitute foreign software modules by new Russian developments.

O. Andreev (supervisor of the work, Gazprom Proyektirovaniye), A. Arabsky, S. Ilyin, O. Gatsolaev, V. Khudyakov, S. Kirsanov, A. Merkulov (Gazprom Dobycha Yamburg).

Nominating company: Gazprom Dobycha Yamburg (O. Arno).

Improvement of the manufacturing technology and setup of the production of a new type of large-diameter pipes for the construction of deep-water offshore gas pipelines with ultrahigh transmission capacity

Aggregate strength properties have been determined for the pipe material to ensure the maximum collapse resistance of the pipe, resistance of the pipe metal to the effects of hydrogen sulfide-containing medium, as well as its good weldability and high impact resistance. The maximum allowable roundness has been set for the mass production of the pipes of the new type, which have a diameter of 32ʺ and are made of X65 strength grade steel with a wall thickness of 39.0 mm.

The possibility was substantiated for reducing metal consumption in the production of the pipes due to the fact that the process chain includes heating of the pipes for the subsequent application of external insulation coating, with this heating operation leading to an increase in the yield strength of the pipe metal to not less than 1.02*SMYS.

Tolerances for wall thickness, diameter, as well as out-of-roundness at pipe ends have been substantiated; it has been demonstrated that the pipe roundness within the set tolerance has practically no effect on the collapse resistance under external pressure.

Design and technical solutions have been introduced as regards the substantiation for choosing pipes with a diameter of 32ʺ of К56 (Х65) strength grade with a wall thickness of 39 mm for the construction of offshore pipelines.

A. Serebryakov (supervisor of the work, Gazprom), E. Solovyov, I. Valiullin (Giprospetsgaz), A. Lobanov, N. Nikolaeva, S. Potapov (Gazprom), A. Blinkov (Intari), A. Parunov (United Metallurgical Company), P. Stepanov (Vyksa Steel Works), A. Fick (South Stream Transport B.V., Gazprom Russkaya).

Nominating company: Giprospetsgaz (O. Andreev).

Creation of innovative methods and technology for the reconstruction of gas wells without well killing with subsequent operation of such wells through concentric tubing

Testing activities have been developed and successfully performed with regard to the technology of well operation through concentric tubing with the use of a special automated complex for controlling and monitoring the well after the reconstruction of the well is performed without killing the well, which makes it possible not to replace the tubing until the end of the useful life of the well.

Reinforced polymer pipes have been developed, along with the technology for running them into the hole as a single length, doing so under pressure without killing the well; the MKRS-20 mobile complex has been created; the equipment has successfully undergone factory and bench tests; the production of the pipes has been set up.

A regulatory framework has been created for the implementation of the technology (5 guidelines and 1 standard of Gazprom).

Working documentation has been developed for well reconstruction; the total actual time required for well reconstruction has been decreased threefold as compared to the time standard provided for by the traditional technology.

S. Mazanov (supervisor of the work), D. Dikamov, A. Koryakin (Gazprom Dobycha Urengoy), V. Minlikaev (Gazprom), R. Gasumov (SevKavNIPIgaz), A. Krasovsky (TyumenNIIgiprogaz), V. Shulyatikov (Gazprom VNIIGAZ), M. Donchenko (Scientific Innovation Enterprise Delta-T), M. Yaremenko (ECO-technologii plus), A. Derevyagin (Scientific Production Association Vympel).

Nominating company: Gazprom Dobycha Urengoy (A. Koryakin).

 

Development and implementation of efficient sci-tech solutions for the production of eco-friendly motor fuels that correspond to K5 class as per the Technical Regulation of the Customs Union (TR CU) 013/2011

Improvements have been introduced into the catalytic reforming technology, as a result of which it has become possible to achieve the characteristics of K5 class as per TR CU 013/2011 during the production of motor fuels at the KR s.100 КОМТ reforming unit of the Chernomyrdin Surgut Condensate Stabilization Plant.

A new domestic catalytic reforming catalyst has been developed and put into use.

A catalyst loading scheme has been developed which makes it possible to use to the maximum extent possible the existing special properties of feedstock for the production of a premium component of gasolines, i.e. catalyzate produced at the catalytic reforming unit.

New cost-effective formulas have been developed and put into use in the production of gasolines.

I. Afanasyev (supervisor of the work, Gazprom), A. Doroshchuk, S. Ivanov, I. Leushin, M. Minkhairov, M. Ovsyankin, P. Solodov (Gazprom Pererabotka), S. Talalaev (Chernomyrdin Surgut Condensate Stabilization Plant, a branch of Gazprom Pererabotka).

Nominating company: Gazprom Pererabotka (Yu. Vazhenin).

Development and creation of a comprehensive automated system for the monitoring of hazardous geological processes at the Dzuarikau – Tskhinval gas pipeline of Gazprom Transgaz Stavropol and the submerged crossing under the Kama River within the Urengoy – Pomary – Uzhgorod gas trunkline (km 1852) of Gazprom Transgaz Tchaikovsky

The required scientific-and-methodological framework has been created for a comprehensive approach to solving a relevant task of ensuring geodynamic safety of gas pipelines.

A system of hardware and methods, as well as an automated system for the control of geological processes, have been developed for real-time monitoring of gas pipeline location parameters within the sections where there is a risk of sudden activation of hazardous geological processes.

On the basis of a radio-frequency method, a pilot monitoring section has been created within the Dzuarikau – Tskhinval gas pipeline network (km 0–92.8), and another pilot monitoring section has been established to cover the landslide slope of the submerged crossing under the Kama River within the Urengoy – Pomary – Uzhgorod gas trunkline.

The newly created system serves to enable prompt managerial decision-making aimed at preventing the development of natural man-made hazardous processes at their early stages; during the work of the systems, a number of emergencies were prevented from arising.

A. Zavgorodnev (supervisor of the work), A. Astanin (Gazprom Transgaz Stavropol), V. Chichelov, R. Khasanov (Gazprom Transgaz Tchaikovsky), M. Zaderigolova (GeoTEK), A. Lopatin (Gubkin Russian State University of Oil and Gas).

Nominating company: Gazprom Transgaz Stavropol (A. Zavgorodnev).

Development and implementation of an innovative method to forecast net gas pay within the Cenomanian complex in order to optimize the extent and timeframes of preparing hydrocarbon reserves for commercial development by drawing on the example of the Kruzenshternskoye field

An innovative method, which represents a new scientific line in seismic data interpretation – chrono-pycnometry, has been developed and implemented to carry out a detailed analysis of time thicknesses within the Cenomanian gas deposit that were detected via 3D seismic survey by common depth point (CDP) method, taking into account well information, with integrated interpretation of seismic data, including structural imaging and dynamic analysis.

The newly introduced method includes a number of procedures that increase the accuracy of imaging and enable a confident mapping of the current net gas pay zones of the Cenomanian deposits being developed, which can serve as the basis for adjusting the development flowsheets for the remaining Cenomanian gas reserves; the implementation of the new method is governed by a corresponding regulatory document.

A. Davydov (supervisor of the work), A. Doroshenko, S. Gorbunov, A. Nezhdanov, V. Ogibenin (Gazprom Geologorazvedka), S. Akhmedsafin, D. Khabibullin, Yu. Pyatnitsky, V. Rybalchenko, I. Sorokin (Gazprom).

Nominating company: Gazprom Geologorazvedka (A. Davydov).

Development and implementation of wellhead repair-and-restoration technologies that use non-standardized equipment

The authors of the paper have developed repair-and-restoration technologies that employ non-standardized equipment, making it possible to perform hydraulic pressure testing, repair and replacement of X-mas tree equipment under pressure, without well killing and with no need to engage well workover crews.

The unique devices are patented; the components of the newly developed devices are 90 per cent of Russian make.

V. Solomakhin (supervisor of the work), V. Kuznetsov, V. Matveev, R. Mullayanov, I. Safonov, V. Skomorokhov, A. Zyulin (Gazprom Gazobezopasnost), D. Belsky (Gazprom).

Nominating company: Gazprom Gazobezopasnost (A. Sorokin).