KAZAKHSTAN

Caspian Sea

Uzbekistan

Kyrgyzstan

DISCOVERED IN 1979, TENGIZ IS ONE OF THE WORLD’S DEEPEST DEVELOPED SUPER GIANT OILFIELDS. THE FUTURE

GROWTH PROJECT (FGP), INTEGRATED WITH THE WELLHEAD PRESSURE MANAGEMENT PROJECT (WPMP), ARE EXE-

CUTED SIMULTANEOUSLY TO EXPAND TENGIZ PRODUCTION AND MAINTAIN FULL PRODUCTION RATES OF THE EXIST-

ING TENGIZ FACILITIES. THE FGP PLANTS WILL NOT PRODUCE SULFUR. THE NATURAL GAS CONTAINING HYDROGEN

SULPHIDE WILL BE RE-INJECTED INTO THE RESERVOIR TO MAINTAIN RESERVOIR PRESSURE. THE EXPANSION IS DE-

SIGNED AND CONSTRUCTED TO OPERATE WITH THE LATEST TECHNOLOGY TO REDUCE AIR EMISSIONS.

FUTURE GROWTH PROJECT (FGP) / KAZAKHSTAN ONSHORE

EPC CONTRACTOR: KPJV / A JV BETWEEN: FLUOR / WORLEY PARSONS / JSC KING AND LLP KGNTEND USER: TENGIZCHEVROIL / A CONSORTIUM OF: CHEVRON / EXXONMOBIL / KAZMUNAYGAS / LUKARKO

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

> HVAC system

> Hydrosanitary system

> Bridge crane

GE’s scope of supply included the fol-

lowing main equipment:

> 110 kV Gas Insulated Switchgear

(GIS) with associated protection,

control and metering equipment

> Utility metering for the 110 kV

interconnection with the Client’s

network

> UPS system and batteries

THE CORE SUBSTATION

The Core substation consists of 32

modules, which were prefabricated,

assembled, sand-blasted, painted

and bolted to form a unique structure.

After completion of the structural and

architectural assembly, the internal

equipment was installed and the sub-

station was tested.

The modules were then disassem-

bled and shipped to Kazakhstan.

The Core substation is built over 2 lev-

els, each divided into rooms. More in

detail, the ground floor includes:

110 kV GIS AREA – Steel struc-

ture made by assembled units which

contain the gas insulated switchgear

(GIS). A 1.5 t bridge crane is installed

over the top floor of the GIS area for

switchgear maintenance purposes.

ELECTRICAL ROOM – 2 transformers

feeding the LV switchgear, UPS, bat-

tery box, and the distribution boards

are installed in the electrical room on

the ground floor, which includes also

an office and a restroom.

BATTERY ROOM – Batteries are locat-

ed 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 – The HVAC LV switch-

gear and PLC panel, the main air

conditioning equipment and the duct

system for the whole substation are

in the HVAC room, which includes

also 2 chemical filters and 2 fans.

INSTRUMENT EQUIPMENT ROOM

This room has been designed for

the control panels supplied by GE.

Access ladders, entrance, emer-

gency and maintenance service

doors complete the substation, and

5 removable panels ensure easy

instal lat ion and maintenance of

the bigger and heavier equipment.

A system of walkways at different

heights serve the electro/instru-

mental paths, starting from the low-

er part beneath the floor beams, all

through the intermediate section, up

to the upper part of the substation,

ensuring the connection among the

main equipment such as GIS, trans-

formers, switchgear, lighting, small

power and sensors from the various

rooms.

ENGINEERING

Skema’s scope of work included all

the design and engineering activities,

which were developed through stud-

ies, calculations, verification and val-

idation, and a series of specific de-

tai led procedures to ensure the

correct sequence of operations to

assemble the modules (e.g. removal

of temporary structural parts; seal-

ing; special tools needed to move the

modules; all that is needed to prepare

the structures for transportation).

3D MODEL

Skema’s supply included a 3D model of

the substation, which gives a 360° view

of the whole substation: structural and

architectural parts, electrical and instru-

mentation, HVAC and control disciplines.

The 3D modeling of the substation and

its equipment enables Skema to ensure

a thorough and consistent monitoring of

the most critical areas, a functional di-

mensional verification of the correct po-

sition of the internal elements in the

various areas, and the removal of any

clashes between the elements of the dis-

ciplines that form the model. It also ena-

bles Skema to interface with its Client

efficiently, giving a unique access key to

the project for the success of both the

engineering and construction phases.

SOLUTIONS DELIVERED

110 KV CORE SUBSTATION

The substation is composed of the following areas: > 110 KV GIS ROOM > ELECTRICAL ROOM > BATTERY ROOM > HVAC ROOM > INSTRUMENT EQUIPMENT ROOM

DIMENSIONS (M) 56 X 14.48 X 7.9 WEIGHT (T) 750

In consortium with GE Grid Solutions, Skema was award-

ed the contract for the sizing, design, engineering, mate-

rials, fabrication, inspection, non-destructive examination,

shop-testing, documentation and preparation for shipment

of the Core 110 kV substation for the TCO FGP project.

The substation was divided into 32 transportable pack-

aged sub-modules complete with integral support struc-

ture, access platforms, stairs, electrical equipment and

building services and including the electrical equipment.

EPC CONTRACTOR: KPJV / A JV BETWEEN: FLUOR / WORLEY PARSONS / JSC KING AND LLP KGNTEND USER: TENGIZCHEVROIL / A CONSORTIUM OF: CHEVRON / EXXONMOBIL / KAZMUNAYGAS / LUKARKO