Gazprom’s Science and Technology Prize

Single-line gas metering station equipped with ultrasonic flow transducers and checked for accuracy by means of an intra-facility verification unit

Nominating company: Gazprom Transgaz Moscow (A. Babakov)

The authors became the first in Russia to develop and implement next-generation metering equipment for large-diameter pipelines on the basis of large-diameter ultrasonic flow transducers checked for accuracy by means of an intra-facility verification unit. All component parts of the equipment are manufactured in Russia.

In the course of their work, the authors have developed a single-line gas metering system comprising the Vympel-500 flangeless ultrasonic metering complex to be installed directly into a gas trunkline, the Vympel-500 ultrasonic metering complex equipped with a reference flow meter (for performing verification (calibration) procedure for large-diameter flow meters), and a block-box for measuring the physical and chemical properties of gas.

The developed technology makes it possible to install (tie-in) the equipment into existing gas trunklines; requires substantially fewer shut-off and control valves, as well as fittings and pipe and tubular products as compared to gas metering systems of the conventional (multi-line) configuration; enables continuous measurements of the volume of natural gas being transmitted through pipelines without suspending the operations in order to carry out maintenance, repairs and verification of the flow meter of DN 1,400 mm; allows to perform verification of the measuring complex directly at the facility with no need to dismantle the said complex and depressurize the system, as well as to operate the gas metering system in automated mode.

Two patents for invention were received with regard to the research paper topic.

Development and implementation of a unique set of technical and engineering solutions for performing 4D seismic monitoring to optimize the control over offshore hydrocarbon field development on the continental shelf of the Russian Federation

Nominating company: Sakhalin Energy (R. Dashkov).

The authors became the first in Russia to develop and implement a unique set of technical and engineering solutions for performing 4D seismic monitoring, with said set of solutions serving as the primary tool to exercise control over offshore hydrocarbon field development and designed to ensure the most effective and efficient development of subsoil resources. The data of 4D seismic monitoring are an invaluable source of information for identifying pay zones and water intrusion zones of the reservoir layer, as well as for designing extended-reach wells and checking the area near the wellbore for its safe technical condition.

In the course of their work, the authors have developed:

• technical design and engineering solutions for conducting field seismic surveys required to perform 4D seismic monitoring, which are adapted to the conditions observed in the Russian Federation;
• a methodology for processing and comprehensive interpretation of the obtained 4D seismic data.

For the purposes of comprehensive data interpretation, a method has been developed for the monitoring of the area near the wellbore based on the difference analysis of the 4D seismic data scattered component. The method has been successfully tested and implemented.

Two patents for invention were received with regard to the research paper topic.

Development and implementation of the methodology and economic-and-mathematical model for strategic planning across the Gazprom Group and in separate businesses

Nominating company: NIIgazeconomika (N. Kislenko).

The authors have developed and implemented a strategic planning system that has no analogues in Russia or abroad; the system was created with the use of strategic targets of the Gazprom Group, including its gas, oil and power businesses, which allows to ensure mutual integration across the Gazprom Group entities, as well as to achieve systemic effects and potential synergy with due consideration of the specifics of Gazprom's activities.

In the course of the work, the authors have accomplished the following tasks:

• the methodology for strategic planning has been developed and implemented across the Gazprom Group and in separate businesses;
• the system of the strategic targets of the Gazprom Group has been created and implemented;
• the unified methodological base of calculation algorithms for projected and actual values of strategic targets has been elaborated as a result of creating a pool of unified and relevant data, as well as adapting the methods for the evaluation of indicators used in the corporate and financial reporting of Gazprom and its subsidiaries to the calculation of projected values;
• methods and principles of presenting the actual financial-and-economic performance indicators of the gas, oil and power businesses of the Gazprom Group in the form of a consolidated balance sheet and comprehensive income statement have been developed, ensuring the comparability with the indicators of the consolidated financial statements of Gazprom and its subsidiaries prepared in accordance with IFRS, as well as the continuity of the methodology applied for generating the projected values of said reporting documents, which established an interconnection between the strategic planning and the financial reporting system of the Gazprom Group;
• the economic-and-mathematical model has been created for calculating the projected operational, financial-and-economic indicators of the long-term development of the Gazprom Group, including strategic targets; the model makes it possible to identify and assess systemic effects in the Gazprom Group and perform a full range of multivariate calculations to aide in long-term planning taking into account different scenarios of macroeconomic indicators, the deadlines and scope of the commissioning of production capacities, as well as the implementation of the key projects of the Gazprom Group and monitoring over the compliance with the specified values of the strategic targets.

A software application was officially registered with regard to the research paper topic.

High-efficiency repair technology for gas trunklines that are prone to stress corrosion cracking

Nominating company: Gazprom VNIIGAZ (M. Nedzvetsky).

The urgency of the research is determined by the need to address the tasks related to ensuring a reliable and safe operation of the linear parts of gas trunklines in the conditions when resources are limited, as well as providing cost optimization with regard to major repairs of the linear parts of gas trunklines.

A high level of stress corrosion defects within the linear parts of gas trunklines requires significant financial expenses for their diagnostic examination and repairs.

In order to reduce the operational costs for purchasing new pipes during repair works on the linear parts of gas trunklines, the authors have developed and implemented the following innovations: a novel approach that makes it possible to extend the lifetime of pipelines with shallow stress corrosion damages; measures to prevent the emergence and expansion of defects caused by stress corrosion cracking (SCC) and measures to obtain reliable data on their dimensions as part of flaw sizing; and a high-efficiency repair technology providing for a several-time reduction of the amount of pipes to be cut out.

It is the first time at Gazprom when:

• an entirely new concept of pipeline lifetime extension, which is based on the hypothesis that minor SCC damages do not threaten pipe safety, has been developed, scientifically substantiated and introduced into production;
• a methodological framework has been elaborated for a reliable assessment of the size of minor cracks caused by SCC with the use of standard tools for non-destructive testing of pipelines;
• a modified bitumen-polymer protective field-applied coating with its primer formula containing a special inhibitor preventing SCC development with a view to eliminating the risk of its re-development has been created, applied in practice and patented.

Three patents for invention were received with regard to the research paper topic.

Technology for the creation and operation of the “well–underground reservoir” system in UGS facilities that are built in rock salt deposits

Nominating company: Gazprom Transgaz Belarus (V. Mayorov).

The urgency of the research is determined by the need for the streamlining of the technologies used in building the infrastructure of underground gas storage (UGS) facilities that are created in rock salt deposits, as well as in improving the operational efficiency, reliability and safety of such facilities. The advantages of said UGS facilities are their impermeability, high deliverability during peak load periods, and the capability of being used in a multiple-cycle operating regime.

Technological solutions have been developed and implemented with regard to the creation of a “well-underground reservoir” system in UGS facilities formed within rock salt deposits which is designed for natural gas storage and further operation of said facilities at the maximum possible level of industrial and blowout safety. The newly developed technology surpasses its foreign analogues.

In the course of the research work, the following technological solutions have been implemented:

• provision of more strength to the well structure by installing an additional production casing in order to prevent gaseous medium from contacting the casing which is prone to mechanical and corrosive wear during the wash-out of the underground reservoir through the lowering and stage-wise open-hole cementing of a new casing string with the use of a hydraulic inflatable packer; lowering and cementing of a new casing string after the installation of a support cement bridge in open hole to separate the reservoir from the wellbore; use of the technology for building a circular cement shell (forming a recess in the wellbore wall);
• technology for cementing of the new casing string with the prior installation of a support polymer-based cement bridge in open hole;
• special complex of underground equipment “Resource-4” which includes a landing nipple, a hydraulic packer, a temperature compensator, a safety valve, and an anchoring device.

One patent of the Republic of Belarus and one patent of the Russian Federation were received with regard to the research paper topic.

Development and commercial introduction of jet units equipped with vortex devices to be used in treatment, processing and storage of oil and petroleum products

Nominating company: Gazprom Neft (A. Dyukov).

The authors became the first to develop a domestic method for calculating the main hydrodynamic and mass-transfer characteristics of jet units equipped with vortex devices.

In the course of their work, the authors have developed:

• theoretical framework for controlling vortex motions in liquids with the purpose of achieving an efficient and safe mixing of oil or petroleum products with other additives (water; water with demulsifier; water with alkali; corrosion inhibitors) in mixing units equipped with vortex devices;
• calculating method for the main hydrodynamic and mass-transfer characteristics of jet units that generate a vortex effect;
• mathematical model for determining rational operational parameters of the mixer, as well as its dimensional characteristics;
• process diagrams for the use of hydraulic-jet mixing units at production sites and refineries, taking into account the operational specifics of relevant enterprises and the quality of oil being processed;
• recommendations on how to draw up technical specifications for the manufacture of mixing units equipped with vortex devices;
• recommendations on how to develop design-and-technical documentation for the manufacture of mixing units which are equipped with vortex devices and use the properties of flow in their work;
• three types of hydraulic jet mixers with vortex effects for oil treatment, storage and transmission: hydraulic jet mixers for oil and heavy oil products (for the elimination of oil sludge), hydraulic jet mixers for fuel (for quick production of high-quality light oil products) and hydraulic jet mixers for oil treatment (for desalting and alkali treatment of oil).

A total of 15 patents for invention were received with regard to the research paper topic.

Application of Data Science tools in petroleum engineering

Nominating company: Gazprom Neft (A. Dyukov).

For the first time ever, a domestic package of digital tools has been created for intellectual analysis of real-time data received from oil wells.

High-frequency telemetry data are analyzed with the use of the so-called hybrid approach, which implies that machine learning is combined with physical processes modeling (hydraulic calculations in the formation and wellbore; calculation of electrical parameters; etc.). For some tasks being addressed, machine learning methods are auxiliary to physical modeling of the analyzed processes, while other tasks are based on machine learning methods and use physical methods only for preliminary verification of the obtained data.

In the course of the research work, the following tools have been created:

• module for the verification and processing of real-time field data received from the production site. The algorithm serves to obtain highly reliable and precise valid data and to provide their further transmission to other modules of the package. The module is also used for detecting malfunctions in sensors and setting up the activities required for the elimination of the defects;
• module for the detection of abnormalities in the performance of the electric centrifugal pump, which makes it possible to promptly analyze the operation of both periodic and permanently active wells on the basis of high-frequency streaming data, as well as to detect active wells that have any complications during operation and recommend the required remedial activities;
• module for the detection of downtimes occurring within a shift, which makes it possible to monitor and control the stability of the stock of gas-lift and flowing wells with the possibility of detecting hydrate formation risks in various units of the production system;
• module for virtual flow measurement, which creates a well flow rate prediction model providing a prompt assessment of the cumulative production by fields/clusters/wells.

The implemented tools cover all main lift methods employed at oil wells (natural flow, gas lift, electric centrifugal pumps).

A total of seven software applications were officially registered with regard to the research paper topic.

Creation of a set of technical solutions for sustainable development of the Bolshoy Urengoy field’s infrastructure on the basis of flexible process flows used for hydrocarbon treatment and transmission

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

The relevance of the research is determined by the need for maintaining reliable gas production at the Bolshoy Urengoy field under the conditions of the formation energy depletion and the downgrading of the resource parameters within the formations of the Cenomanian gas deposit and Valanginian gas condensate deposits.

The technical solutions proposed in the research work are aimed at eliminating the problems associated with the use of shut-off and control valves at the comprehensive gas treatment units (CGTUs) that work with the Cenomanian gas, reduction of formation pressure to the values below the design level, construction of pipelines for supplying commercial gas from CGTU-11V to the nearby booster compressor station (BCS) of the Cenomanian deposit and launch of an in-field BCS at the Valanginian deposits, as well as the dependency of work of the BCSs of the Valanginian deposits on the processing facilities of the Condensate Treatment Plant of Gazprom Pererabotka.

For the first time ever, technical solutions were introduced for optimizing the work of the CGTUs with the use of newly vacant capacities of the BCSs of the Cenomanian deposit for compressing commercial gas at the BCSs of the Valanginian deposits.

The objectives reached in the course of the research work are as follows:

• the workload of the inter-field header was analyzed with the participation of Gazprom VNIIGAZ. To address the problem of the suspension of gas production which is going to occur due to the reconstruction of the BCSs, it was proposed to jointly operate the production sites with the use of one of the pipelines belonging to the inter-field header;

• to minimize the scope of reconstruction works, the production sites were grouped for the purpose of low-pressure gas transmission via new pipelines, and three- and four-stage compression was performed at two production sites;
• the second process string of the inter-field header was chosen to serve as the low-pressure pipeline for transmitting gas between the production sites. The pipeline delivers gas to the main CGTUs which send treated and compressed gas to the first process string of the inter-field header and further to main compressor stations. CGTU-4, CGTU-7 and CGTU-12 were chosen as the main production sites, as their wellhead pressures are lower than those of adjacent production sites, which enables transmission of gas under its own pressure;
• CGTU-4, CGTU-7 and CGTU-12 and the pipelines connecting them to the inter-field header were reconstructed so that gas could be delivered from other satellite production sites.

Three patents for inventions were received with regard to the research paper topic.

Development of a combined ultrasound cleaning method for burner devices

Nominating company: Gazprom Transgaz Saratov (V. Mironov).

The urgency of the research is determined by the need for increasing the operating efficiency of burner devices installed in low-emission combustion chambers at gas compressor units (GCUs).

In both Russian and foreign practice, this is the first-ever method developed for combined ultrasonic cleaning of burner devices providing for the restoration of their performance efficiency and parameters to the values recorded in their technical passports through creating ultrasonic vibrations directly inside the devices.

In the course of the research work, the following activities have been carried out:

• the existing practical experience of restoring the flow rate of burner devices by means of ultrasonic cleaning was analyzed;
• an ultrasonic cleaning method was developed which implies decontamination through creating a bending stress in the elements of the items being cleaned which exceeds the adhesive strength of the elements' layer;
• successful experiments were held to test and substantiate the new process of combined ultrasonic cleaning of openings and channels in burner devices installed at GT-750-6 gas compressor units;
• simulation of loading experienced by a burner device during cleaning was performed; the effective range of regimes was determined for the cleaning procedure; the method and process flow diagram of the cleaning procedure were substantiated; the cleaning technology underwent experimental tests;
• operating regimes to be applied during the cleaning and the technical requirements to the automated ultrasonic cleaning unit with active control of the changes in the expenditure of the cleaning agent in the burner device being cleaned were substantiated;
• a prototype cleaning unit complete with a package of design documentation was developed and manufactured;
• tests were performed on sets of burner devices to check the performance of the cleaning unit, which confirmed that the newly developed ultrasonic cleaning method is effective (the efficiency of burner devices tested increased by 6 per cent; the normalized concentration of NOx and CO compounds in dry burnt gases decreased by 4.3 and 7.5 times, correspondingly, which is practically the same as the parameters of a new device).

One patent for invention was received with regard to the research paper topic.

Automated information system for the control and management of innovations development

Nominating company: Gazprom Dobycha Astrakhan (A. Melnichenko).

The urgency of the research is determined by the need for creating an integrated information environment and an automated control system at Gazprom for the participants of the innovations generation process, as well as the process of consideration and approval of innovations and their further implementation and use in production and business activities.

The new automated information system for the control and management of innovations development is a comprehensive automated organizational solution that helps enhance the development of innovative activities at the organizational level across Gazprom. The automated information system for the control and management of innovations development conforms to the requirements of the STO Gazprom standards of the “Intellectual Activities” series and possesses a wide range of functions.

The automated information system for the control and management of innovations development makes it possible to:

• ensure the creation of a single software environment for the participants of innovations development process across Gazprom;
• reduce the time required for the preparation, adoption and implementation of innovative solutions;
• organize monitoring of innovations development indicators at different management levels;
• ensure that the budget indicators of innovations development are formed with due reliability and validity;
• create a possibility of upscaling and reproducing innovations across the subsidiaries.

One utility patent was received and four software applications were officially registered with regard to the research paper topic.