JSC TATNEFT jointly with ZAO "Tatex" continues the work aimed at ensuring the rational use of associated petroleum gas (APG). The second program to improve efficient produced gas utilization is being implemented in TATNEFT. In the framework of this program Capstone micro-turbine power plants are implemented.
Rustam Minnikhanov, President of Tatarstan, got familiarized with a successful application of Capstone gas turbine plants for power generation from produced petroleum gas containing hydrogen sulfide. During a working visit Head of the Republic was accompanied by Shafagat Takhautdinov, General Director of JSC TATNEFT, and Irek Khairullin, General Director of ZAO "Tatex". The operating principle of Capstone micro-turbine power plants was clearly demonstrated to the President of the Republic at Onbiyskoye field DNS-30 (booster pumping station) of ZAO "Tatex". Similar gas turbine plants have been operating in the Republic since 2012 at Oil & Gas Production Boards of TATNEFT: "Yamashneft", "Bavlyneft" and "Elkhovneft", as well as at JSC "Tatoilgaz."
There are 24 gas turbine plants installed at JSC TATNEFT at present to improve the efficient utilization of produced associated gas. A specific feature of the Capstone turbines is the layout of the main components of the unit, which provides for placement of compressor, combustion chamber, regenerative heat exchanger, turbine and electric generator permanent magnets within a compact body. The generator is cooled by the airstream, which eliminates the need for a liquid cooling system arrangement and increases the reliability and efficiency of the equipment in service. A design feature of the engine is application of air bearings, which eliminates the necessity of using oil for lubrication. The shaft rotation speed is 62,000 rpm. The oilmen of the Republic started the experiment with Capstone in 2007 when a 30 kW micro-turbine was put into operation. Given a successful five-year experience of the plant’s operation, it was decided to build a more powerful gas turbine station with a total capacity of 1,600 kW. Two gas turbine plants of 800 kW capacity were commissioned in 2012, each of them composed of four 200 kW micro-turbine units. Today they successfully utilize produced associated hydrogen sulfide containing petroleum gas to generate electricity.
The plant consumes on average 12.5 thousand cubic meters of associated petroleum gas per day and generates about 30,720 kW of energy. One turbine consumes from 59 to 62 cubic meters of gas per hour. 0.3 cubic meter of gas is required for generation of 1 kW of energy. The resulting electricity allows covering 60-65 per cent of the production facilities needs at Onbiyskoye field owned by ZAO "Tatex". The payback period is about 6 years. Rustam Minnikhanov also inspected the operator's room of the booster pumping station, where the supervision of the facilities' operation is performed, including the gas turbine station.
The Power monitor displays the entire process of the plant. Using this program, technicians can Electricity monitor the process mode of the whole gas turbine plant complex starting with gas supply to the booster compressor station to gas feeding to the turbine. The turbine operation control system is based on application of the microprocessor automatic control system that allows Home electricity monitorthe plant’s operation by the existing staff. In addition, the possibility of using "remote control" is provided that allows professionals to diagnose and change operating parameters without going to the facility. The Head of the Republic highly assessed the work of Tatarstan oilmen in the field of associated petroleum gas utilization; it is the task of national importance today. In 2012 the Russian Federation government established a strict requirement of 95 percent utilization of associated petroleum gas. JSC TATNEFT has been the first company in Russia to ensure a 95 percent level of associated petroleum gas utilization.
The penalties for flaring associated petroleum gas have increased by 12 times since January 2013 and they will increase by 25 times in 2014. The implementation of TATNEFT's program to enhance the efficient utilization of produced associated gas will provide a guaranteed level of efficient associated gas utilization on the one hand, and on the other hand the oil production facilities, including the most remote ones, will be provided with its own electric power.