FUTURE GROWTH/WELLHEADPRESSURE MANAGEMENT

110 kV GIS CORE & MAIN SUBSTATIONS

DISCOVERED IN 1979, TENGIZ IS ONE OF THE WORLD’S DEEPEST PRODUCING SUPER GIANT OILFIELDS AND ONE OF THE LARGEST DISCOVERIES IN RECENT HISTORY.

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FGP/WPMP PROJECTLOCATED IN A REMOTE AREA OF WEST-ERN KAZAKHSTAN, THE UNDERGROUND TENGIZ RESERVOIR MEASURES 20 KILOMETRES BY 21 KILOMETRES. THE ENTIRE TENGIZ OILFIELD AREA IS ESTI-MATED TO CONTAIN 750 MILLION TO 1.1 BILLION METRIC TONNES (6 TO 9 BIL-LION BARRELS) OF RECOVERABLE OIL.

KAZAKHSTAN

Caspian Sea Uzbekistan Kyrgyzstan

Russia

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SKEMA FOR THE TENGIZ FGP/WPMP PROJECTCORE & MAIN SUBSTATIONS

IN CONSORTIUM WITH GE GRID SOLUTIONS, SKEMA WAS

AWARDED THE CONTRACT FOR THE DESIGN, ENGINEER-

ING, DEVELOPMENT, FABRICATION, ELECTRICAL EQUIP-

MENT, MULTIDISCIPLINARY INSTALLATION ACTIVITIES,

INSPECTION, TESTING PROGRAM, DOCUMENTATION AND

PRESERVATION FOR SHIPMENT OF THE 110 kV CORE AND

MAIN SUBSTATIONS FOR THE TCO FGP/WPMP PROJECT.

The substations were divided into transportable packaged sub-

modules complete with access platforms, stairs, electrical equip-

ment and building services.

“On behalf of our team, I would like to express our deep gratitude to the Skema team involved in Main substation design, development,

fabrication, and testing program. We appreciate your strong capabilities and commitment establishing effective cooperation and communication

with us and all the specialists from supporting companies. Your professionalism allowed us to achieve our targeted shipment date with

a high-quality work product. This large and complex scope has been completed with a total of 637 days of Incident and Injury Free work.

This is a great accomplishment and very important achievement for the TCO Future Growth Project and for all of us.

TCO appreciates SKEMA for their partnership in this work.”

Senior Project Manager,FGP/WPMP Project

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SKEMA’S SCOPE OF WORK

Skema was awarded the contract for the sizing, design, materials, fabrication, inspection, non-destructive examination, shop-

testing, documentation and preparation for shipment of the 110 kV GIS Core and Main substations. The Core substation was

divided into 32 transportable packaged sub-modules for sea and road transportation and the Main substation into 2 mod-

ules for sea and road transportation. Performance was according to IEC/GOST standards and PUE ROK.

EPC CONTRACTOR: KPJV / A JV BETWEEN FLUOR, WORLEY PARSONS, JSC KING AND LLP KGNT

END USER: TENGIZCHEVROIL / A CONSORTIUM OF CHEVRON, EXXONMOBIL, KAZMUNAIGAS, LUKARKO

CORE SUBSTATION SHIPPED IN 32 MODULES

LENGTH 81.1 M

WIDTH 14.48 M

HEIGHT 8.6 M

HEIGHT 7.9 M

WEIGHT 1,097 T

WEIGHT 750 T

WIDTH 14.6 M

LENGTH 56 M

MAIN SUBSTATION SHIPPED IN 2 MODULES

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ENGINEERING

THE DESIGN AND ENGINEERING

OF THE CORE AND MAIN MODU-

LAR SUBSTATIONS WERE DEVEL-

OPED THROUGH STUDIES, CALCU-

LATIONS, DRAWINGS, VERIFICATIONS

AND VALIDATIONS, AND A SE-

RIES OF SPECIFIC DETAILED PRO-

CEDURES TO ENSURE THE COR-

RECT SEQUENCE OF ASSEMBLY

AND TESTING OPERATIONS ON SITE.

The structure of the substations, man-

ufactured in steel and installed above

concrete foundations, was designed

to meet all the requirements defined

in the Client’s specifications.

A complete three-dimensional com-

puter model of the structure was de-

veloped, using a dedicated calcula-

tion software, in order to perform the

analysis for all conditions applicable

to the substation, as detailed below:

> Structural in-service analysis

> Structural lifting analysis

> Structural transportation analysis

The analyses, which included the

structural verifications of all weld-

ed and bolted joints, were carried

out considering the gravity loads of

the structure and equipment, com-

bined with the dynamic loads and

environmental loads (such as wind,

seismic, snow, thermal and blast) ap-

plicable to each specific condition.

A set of detailed structural and ar-

chitectural drawings, representing

the actual structural and architec-

tural design and providing all nec-

essary input for construction, were

developed according to the re-

sults of the structural analyses.

Dedicated calculations, drawings,

technical documentation and installa-

tion details were also developed to de-

sign each system, including the main

equipment, to comply with all pro-

ject and environmental requirements.

Drawings and documentation (in-

cluding Procedures, Passports,

Manufacturing Record Books, Dis-

patch Dossiers) were provided most-

ly in dual language (Russian and

English), while the Installation Op-

erating and Maintenance Manu-

als were provided in three languag-

es (Kazakh, Russian and English).

3D MODEL – Skema developed a 3D

model of each substation, that allows

a 360° view of the whole substation

complete with structural and archi-

tectural parts, electrical and instru-

mentation, HVAC and F&G systems.

The 3D model of the substation and

its equipment enables Skema to en-

sure a thorough and consistent mon-

itoring of the most critical areas, a

functional dimensional verification of

the correct position of the internal el-

ements in the various areas, and the

removal of any clashes between the

elements of the disciplines. It also en-

ables Skema to interface with its Cli-

ent efficiently, giving a unique access

key to the project for the success of

both the engineering and construc-

tion phases.

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CORE SUBSTATION 32 MODULES

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CORE SUBSTATION 32 MODULES

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MAIN SUBSTATION 2 MODULES

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MAIN SUBSTATION 2 MODULES

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THE CORE SUBSTATION CONSISTS OF

32 MODULES, WHICH WERE PREFAB-

RICATED, ASSEMBLED, SAND-BLAST-

ED, PAINTED AND BOLTED TO FORM A

UNIQUE STRUCTURE. AFTER COMPLE-

TION OF THE STRUCTURAL AND AR-

CHITECTURAL ASSEMBLY, THE INTER-

NAL EQUIPMENT WAS INSTALLED AND

THE SUBSTATION WAS TESTED. THE

MODULES WERE THEN DISASSEM-

BLED AND SHIPPED TO KAZAKHSTAN.

The Core substation is built over

2 levels, each divided into rooms. More

in detail, the ground floor includes:

110 kV GIS AREA (18 modules)

Steel structure made by assembled

units which contain the gas insulated

switchgear (GIS). A 1.5 t bridge crane

is installed at elevation level of the

GIS area for switchgear maintenance

purposes.

ELECTRICAL ROOM (6 modules)

2 transformers feeding the LV switch-

gear, UPS, battery box, and the distribu-

tion boards are installed in the electri-

cal room on the ground floor, which

includes also an office and a restroom.

BATTERY ROOM (1 module) – Bat-

teries are located on specific racks in

this room, which is equipped with an

eye wash facility and a trolley to move

the batteries.

The mezzanine floor hosts:

HVAC ROOM (5 modules) – The HVAC

LV switchgear and PLC panel, the main

air conditioning equipment and the duct

system for the whole substation are lo-

cated in the HVAC room, which includes

also 2 chemical filters and 2 fans.

INSTRUMENT EQUIPMENT ROOM

(2 modules) – This room has been

designed to host the control panels.

Access ladders, entrance, emergency

and maintenance service doors com-

plete the substation, and 5 removable

panels ensure easy installation and

maintenance of the bigger and heavier

equipment. A system of cable trays at

different heights serve the electro/

instrumental paths, starting from the

lower part beneath the floor beams, all

through the intermediate section, up to

the upper part of the substation, ensur-

ing the connection among the main

equipment such as GIS, transformers,

switchgear, lighting, small power and

sensors from the various rooms.

THE EQUIPMENT

Skema provided the following main

equipment for the 110 kV Core sub-

station:

> LV Switchgear and MCCs com-

plete with auto-transfer scheme,

momentary synchronizing be-

tween incomers, switchgear and

transformer protection, control

and metering equipment

> Distribution Boards, Bus Ducts,

Distribution Transformers and PLC

panel

> Electrical/Instruments and F&G

systems, internal and external

lighting

> HVAC system

> Hydrosanitary system

> Bridge crane

THE CORE SUBSTATION

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THE MAIN SUBSTATION, WHICH IS

THE LARGEST SUBSTATION OF THE

OVERALL FUTURE GROWTH PRO-

JECT, CONSISTS OF 2 MODULES

WHICH WERE PREFABRICATED,

ASSEMBLED, SAND-BLASTED,

PAINTED AND BOLTED TO FORM A

UNIQUE STRUCTURE. THE MODULES

WERE THEN DISASSEMBLED AND

SHIPPED TO KAZAKHSTAN BY BARGE.

The Main substation is built over 2

levels, each divided into rooms. More

in detail, the Utility Module includes

the Battery Room and the Electrical

Room on the ground floor, and the

HVAC Room and Instrument Equip-

ment Room on the mezzanine floor.

The GIS module corresponds to the

GIS area which includes the 110 kV

GIS switchgear with the control panels

and a 1.5 t bridge crane for GIS main-

tenance. Access ladders entrance,

emergency and maintenance service

doors complete the substation, and 3

removable panels ensure easy instal-

lation and maintenance of the bigger

and heavier equipment. The substa-

tion is complete with air conditioning,

electro/instrumental and Fire and Gas

systems. A system of cable trays at

different heights serve the electro/

instrumental paths, starting from the

lower part beneath the floor beams, all

through the intermediate section, up

to the upper part of the substation, en-

suring the connection among the main

equipment such as GIS, transform-

ers, switchgear, lighting, small power

and sensors from the various rooms.

110 kV GIS AREA (Gis module) – This

module contains the gas insulated

switchgear (GIS). A 1.5 t bridge crane is

installed at elevation level of the GIS area

for switchgear maintenance purposes.

ELECTRICAL ROOM (Utility module)

3 transformers feeding the LV

switchgear, UPS, and the distribution

boards are installed in the electrical

room, which also includes an office

and a restroom.

BATTERY ROOM (Utility module)

Batteries are located on specific racks

in this room, which is equipped with

an eye wash facility and a trolley

to move the batteries.

The mezzanine floor hosts:

HVAC ROOM (Utility module) – The

HVAC LV switchgear and PLC panel,

the main air conditioning equipment

and the duct system for the whole

substation are located in the HVAC

room, which includes also 2 chemical

filters and 2 fans.

INSTRUMENT EQUIPMENT ROOM

(Utility module) – This room has been

designed to host control panels.

THE EQUIPMENT

Skema provided the following main

equipment for the 110 kV Main sub-

station:

> LV Switchgear and MCCs com-

plete with auto-transfer scheme,

momentary synchronizing be-

tween incomers, switchgear and

transformer protection, control

and metering equipment

> Distribution Boards, Bus Ducts,

Distribution Transformers and

PLC panel

> Electrical/Instruments and F&G

systems, internal and external

lighting

> HVAC system

> Bridge crane

THE MAIN SUBSTATION

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SKEMA HAS DEVELOPED THROUGH

AN EXTENSIVE PROJECT EXPERIENCE,

A WIDE KNOWLEDGE AND EXPERTISE

WITH REGARDS TO OPERATIONS RE-

LATED TO PRESERVATION, DISASSEM-

BLY, LIFTING, HANDLING AND LOAD

OUT OF MODULAR SUBSTATIONS.

PRESERVATION AND DISASSEMBLY

For the Core and Main substations,

Skema supplied the following services:

> Preservation, protection and stor-

age at the fabrication yard

> Disassembly in modules

> Packaging, preservation and pro-

tection for sea and land transport

> Winterization for shipment and

storage

> Load out

Preservation procedures were pro-

vided to give guidance till the mod-

ules shipment to Kazakhstan and from

shipment to Kazakhstan up to the op-

eration of the substation.

LOAD OUT - The substations were pre-

pared for load out by removing all the

external items (e.g. rain hoods, ex-

ternal lighting, F&G and HVAC items)

which were properly packed and fixed

inside the modules or shipped as loose

items inside standard containers.

All the internal equipment was stead-

ily fixed to the designed supports,

and all the cabinets doors locked.

The openings on the external clad-

dings, like MCTs or HVAC sleeves,

were closed from outside, and sealed

all over to avoid penetration of dust

and water. Once the preparation was

completed, the substations modules

were moved, by means of Self Pro-

pelled Modular Transporters (SPMTs),

and positioned along yard quay ready

to be handed over to the Client for sea

transportation.

INSTALLATION MANUAL - Skema pro-

vided detailed Installation Manuals

containing Safety tips and operating

instructions for the unloading, handling

and reassembly of the modules onsite.

Dedicated installation manuals were

also provided for all dismantled items

to allow a proper reinstallation at site

of all plants and equipment belonging

to the substations.

DISASSEMBLY, LOAD OUT AND TRANSPORTATION

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THANK YOU FOR WORKING WITH SKEMA!“During my career I chose to be passionate and have pride for

work, and this has become part of Skema’s company values

as well. The desire for continuous improvement and the metic-

ulous attention to detail in an effort to deliver superior quality

and to exceed our Clients’ expectations has become the mis-

sion of the company. I would like to thank our Clients for their

trust and valued collaboration and all the workers and all the

subcontractors involved, that with blood, sweat and tears, made

possible the completion of the Core and Main substations in

compliance with the specifications and the safety requirements

of this challenging project.”

Mario Cerveglieri - President

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www.skemaq.it