Gazprom’s Science and Technology Prize

Corporate management system for energy efficiency and greenhouse gas emissions at Gazprom

The research work introduces a corporate system providing information support of managerial decisions aimed at achieving the key indicators related to energy and resource saving at Gazprom. The system offers a comprehensive solution to the challenge of reducing the amount of energy resources used for internal process needs and minimizing greenhouse gas emissions.

In the course of the research work:

• feasibility studies have been performed with regard to the role and place of natural gas in the energy market, taking into account the environmental advantages of this energy source; a method has been developed to assess the carbon footprint in the lifecycle of Russian natural gas, from production to consumer deliveries;
• national greenhouse gas emission factors for the Russian oil and gas industry have been developed and implemented at the international and federal levels;
• in the course of experimental studies, the inexpediency of hygienic rating of methane as individual pollutant in the air of residential areas has been substantiated;
• a register of the best available technologies for use at Gazprom's facilities has been formed to ensure energy, economic and environmental efficiency;
• studies have been performed to assess the lifecycle of NGV fuel, gasoline and diesel fuel. The authors of the research work have assessed specific pollutant emissions, as well as “carbon” footprint and “toxic” footprint (the latter term has been introduced by the authors for the first time ever) for various types of oil- and gas-based motor fuels, taking into account the lifecycle from feedstock production to fuel combustion in vehicles;
• a domestic model for assessing greenhouse gas emissions throughout the lifecycle of hydrocarbon feedstock (natural gas, oil, condensate, etc.) from the wellhead to the consumer has been developed, which makes it possible to perform a reliable assessment of the lifecycle of exported Russian natural gas and confirm the high level of eco-friendliness of natural gas at every stage from the wellhead to the consumer, considering that the international community pays particular attention to the environmental aspect of a process/product;
• expert studies have been carried out which proved that carbon footprint of Russian natural gas being supplied to Central Europe is 48 per cent below the value published in the Exergia study based on 2012 data that was performed by order of the European Commission. As compared to 2015 indicators, said value has reduced by 61 per cent due to annual upgrade activities and the increase in the share of exports via the Nord Stream gas pipeline;
• corporate Energy Saving and Energy Efficiency Programs have been developed providing for the implementation of the activities aimed at saving fuel gas and reducing greenhouse gas emissions into the atmosphere at Gazprom's facilities. The cumulative fuel and energy savings in 2011–2016 amounted to 15.3 million tons of fuel equivalent. Greenhouse gas emissions were reduced by 32.2 million tons of CO2 equivalent in 2016 versus 2011;
• more than 30 intergovernmental, federal and corporate regulatory documents have been developed.

The economic benefits from the implemented system are as follows:

• reduction of payments for pollutant emissions (including methane) into the atmosphere;
• reduction of energy consumption (first of all, natural gas consumption) for internal process needs.

A. Ishkov (supervisor of the work, Gazprom), G. Akopova, G. Khvorov, E. Kosolapova, N. Pystina (Gazprom VNIIGAZ), E. Fomichev, A. Melkov, K. Romanov (Gazprom), E. Varfolomeev (NIIgazeconomika) – for the paper entitled “Corporate management system for energy efficiency and greenhouse gas emissions at Gazprom.”

Nominating company: Gazprom VNIIGAZ.

High-resolution technology in production well diagnostics

In Russian practice, this is the first time ever that ultrasonic methods for detecting flaws in metal products have been successfully applied for the inspection of the underground equipment of wells that has peculiarities distinguishing it from the above-ground facilities in terms of the possibility of flaw detection activities;

the use of an optimal complex of domestic geophysical instruments has been substantiated, which makes it possible to use high-resolution technology (hereinafter – HRT) for the diagnostics of the technical condition of wells, including acoustic methods and multi-finger caliper logging;

theoretical and experimental studies of the physical principles of ultrasonic sounding in a multi-layer structure have been performed, and the patterns of acoustic signal propagation depending on the implemented physical principle have been defined;

a classification of corrosion and wear mechanisms on the internal and external surface of casings and a classification of the defects depending on the resolution characteristics have been developed. The latter classification makes it possible to perform the lifetime calculations of casing stings in standard and nonstandard conditions;

methods for qualitative processing and interpretation of the HRT data have been developed, which makes it possible to assess the technical condition of casings, detect and identify pipe defects, and define their dimensions both on the internal and external surface of casing strings;

a comparative analysis has been performed with regard to the technical characteristics of foreign and domestic geophysical instruments providing for the use of HRT for the diagnostics of the technical condition of wells;

calibration devices have been developed, manufactured and introduced into production to provide the metrological verification of high-resolution instruments and obtain a reliable information about the technical condition of wells;

software applications have been developed for digital processing of a big amount of geophysical data, as well as arranging and displaying information in various formats;

analysis and improvement of the technology for the preparation of well for HRT testing have been performed, and technical requirements to casing cleaning tools have been developed.

As a result of using high-resolution technology, the safe operation time between overhauls has increased from 10 to 15 years.

The research work introduces a comprehensive technology for the technical diagnostics of the underground equipment of production wells, which includes a methodology and a complex of instruments for arranging the works and performing ultrasonic flaw detection, as well as deciphering and interpreting the flaw detection data with the assessment of the technical condition of wells.

V. Plotnikov (supervisor of the work, Gazprom Georesource), V. Maslennikov, V. Shulaev (Gazprom Georesource), A. Kalinkin, I. Zinchenko (Gazprom), A. Komarov, V. Kunavin, I. Polyakov (Gazprom Dobycha Astrakhan), A. Istomin, B. Pavlovsky (“Institute of Physical Diagnostics and Modeling” Foundation).

Nominating company: Gazprom Georesource.

Development and introduction of advanced technologies for strength tests, dewatering and commissioning of Gazprom’s gas pipelines

The research work introduces a summarization of the results regarding the implementation at Gazprom's facilities of the technologies aimed at preparing the newly built gas trunklines for acceptance and commissioning procedures (strength tests, dewatering and filling with natural gas during pipeline commissioning at the final stage of construction works);

developed technologies are based on the results of theoretical works and studies regarding the stress-related properties of pipes and gas dynamic processes that accompany strength tests, as well as the tests of the kinetics and dynamics of moisture and heat transfer during gas pipeline dewatering after testing;

technological solutions are protected by 9 patents for inventions that are widely used in the course of building Gazprom's gas transmission facilities;

regulatory documents with the STO Gazprom status specifying the use of the developed technologies are available;

a training course for the students of the Gubkin Russian State University of Oil and Gas has been developed.

B. Zhitomirsky (supervisor of the work, Orgenergogaz), V. Dubinsky, D. Kudryavtsev, D. Lyapichev, V. Shabanov (Orgenergogaz), V. Borodin, A. Livin, S. Prozorov (Gazprom), K. Vyskrebentsev, A. Zykin (Orgtruboprovodservice).

Nominating company: Orgenergogaz.

Development, manufacturing and introduction of prototypes of the Kvant-R automatic control system for gas compressor units, RIUS-R automatic process control system for compressor workshops, and PK VEGA-R automatic fire-fighting and gas hazard monitoring system using Russian software and hardware

Improvements have been introduced into the software and hardware that are currently used for the collection and production of signals; the ACS software (of the lower and upper levels), as well as the operating system of the microprocessor-based module of the ACS for GCU, have been revised;

functions have been added to ensure compliance with the information protection requirements;

real-world testing of the applied components of Russian make has been performed at the facility of their intended use, as a result of which some of the components have been replaced with analogues during the pilot operation, as they failed to satisfy the reliability specifications stated.

Due to the use of the Elbrus and Sonet domestic software and hardware in the course of the work, the newly developed ACS has the following advantages:

• it can be used for all types of GCUs (GCUs equipped with the aircraft drive based on GCU NK-12SТ, PS-90 developed by JSC “UEC-Aviadvigatel”; GCU-4RM developed by JSC “Saturn”);
• it can perform the parametric diagnostics of the GCUs' condition;
• it can detect the stress condition of process pipelines;
• it can implement the control algorithms of the magnetic suspension of GCU compressors;
• it can implement the algorithms of fuel valve regulation, anti-surge control and load distribution so that no specialized controllers are required;
• it can record all analog and discrete parameters in real-time mode, including the parameters involved in fast regulation algorithms;
• the SCADA system of Sonata is compatible with automated workstations that run the Russian real-time operating system Elbrus and use processors of Russian make;
• the ACS can be used for the control of actuators with frequency regulation.

Adoption of systems that are based on Russian software, hardware and components ensures the implementation of Gazprom's import substitution policy, considerably reduces the dependence on foreign manufacturers with regard to automation equipment and systems, reduces the time required for the production of ACSs due to minimized risks of delays in the delivery of the required components, enables prompt technical support from the manufacturers of components and software, provides for a stepwise reduction of expenses for the creation of automation equipment and systems of various levels of complexity, and enhances the information protection of ACSs.

S. Marchenko (supervisor of the work, Gazprom Transgaz Moscow), A. Lyashenko, A. Mazur, A. Semenov, M. Zhelnov (Gazprom Transgaz Moscow), P. Semenov (Gazprom), D. Egortsev, A. Naumets, V. Usenko, A. Vodennikov (Vega-GAZ).

Nominating company: Gazprom Transgaz Moscow.

Development and introduction of domestic equipment at the facilities of the Astrakhanskoye gas and condensate field

As a result of the research, equipment manufactured by Russian machine-building enterprises has been adopted at the facilities of Gazprom Dobycha Astrakhan instead of imported equipment and component parts; the newly adopted domestic equipment meets the increased requirements and is highly resistant to corrosive components present in the product produced and processed at said facilities.

The newly developed equipment has a number of advantages as compared to its foreign counterparts, namely:

• increased reliability due to the use of improved structural solutions and enhanced materials, for instance, use of weld overlay to add special alloys and steels on internal surfaces;
• increased estimated service life;
• lower cost as compared to imported analogues.

The equipment has been adopted at the piping of wellheads and gas pre-treatment units, as well as at the process units of the gas processing plant of Gazprom Dobycha Astrakhan.

A. Melnichenko (supervisor of the work, Gazprom Dobycha Astrakhan), G. Afanasov, A. Ekotov, A. Korenyakin, N. Nizamov, N. Rylov (Gazprom Dobycha Astrakhan), V. Artemenkov, A. Filippov, V. Vavilov (Gazprom), B. Erekhinsky (retiree).

Nominating company: Gazprom Dobycha Astrakhan.

Design and creation of a non-intrusive diagnostics kit for infield pipelines in need of essential repairs

The research work introduces a non-intrusive diagnostics kit that consists of a system of three-component ferroprobe magnetometer/gradiometers and magnetometers for variable magnetic field designed for the inspection of infield pipelines. The system includes:

• sets of non-intrusive diagnostics tools equipped with three-component ferroprobe magnetometer/gradiometers and magnetometers for variable magnetic field, which, for the first time ever in the global practice, make it possible to measure the entire gradient matrix within the static magnetic field of a pipeline, and thus to detect flaws of various nature, classify and rank them;
• antennae systems of induction transducers, with the use of voice recommendations on the pipeline route location and determination of its depth;
• software for automated search, identification and assessment of pipeline flaws.

The scientific novelty of the technical solutions is confirmed by 6 patents for inventions which are valid in the territory of the Russian Federation.

The economic benefits brought about by the implementation of the project for the non-intrusive diagnostics kit are as follows:

• decrease of the flow of failures and, accordingly, reduction of the burden on the environment;
• reduction in the amount of repair works for pipeline replacement owing to spot repair of the flaws detected.

A. Shushakov, G. Maximov, F. Nosov (Gazprom Neft), A. Eliseev, V. Semenov, A. Fogel (Diagnosticheskiye Sistemy LLC) – for the paper titled “Design and creation of a non-intrusive diagnostics kit for infield pipelines in need of essential repairs.”

Nominating company: Gazprom Neft.

Methodology and software for estimating the limit cost of pre-investment studies

The research work introduces tools for estimating the limit cost of pre-investment studies, i. e. a methodology and a respective software that make it possible, with moderate labor input, to rapidly estimate the limit cost of pre-investment studies for the needs of Gazprom using standardized approaches and taking into account the requirements stipulated in the research assignment.

The authors have developed an entirely new concept for estimating the limit cost of pre-investment studies that takes into account not only macroeconomic characteristics, but also industry specifics. Inter alia, a list of the areas of pre-investment studies, a method for assessing the average cost of said areas of studies, simplification and complexity factors related to said areas of studies, and the range of influence of each identified factor have been defined and outlined for the first time ever.

The performed statistical & mathematical studies and computational experiments have shown a significant superiority of the developed methodology and software for assessing the limit cost of pre-investment studies in terms of validity, efficiency and labor input not only over approaches and methods that are currently used in global practice, but also over the method for assessing labor input on the basis of expert estimates and review of analogs that had been used before the introduction of said development.

The use of said development in the course of tender procedures makes it possible to significantly enhance the quality of made decisions and reduce the influence of subjective factors when identifying the cost of pre-investment studies.

The developed software application was officially registered.

The results of the research work provide an economic benefit by reducing the expenditures for performing pre-investment studies through the substantiated minimization of the initial cost of works in the course of tender procedures for contractor selection, as well as by increasing the validity and efficiency of managerial decisions when estimating the cost of pre-investment studies performed for the needs of Gazprom.

A. Skrepnyuk (supervisor of the work, Gazprom), O. Kirichenko, A. Komzolov, I. Kuznetsov, O. Nasikovskaya (NIIgazeconomika), N. Chaika, V. Savchenko, I. Shabalov (Gazprom), A. Nikanorova, S. Vaulina (retirees).

Nominating company: NIIgazeconomika.