ETC CKBN, LTD is a specialized organization providing the full range of services in the area of industrial safety, modernization and repair, development and delivery of technological equipment. Purpose We think that our mission is to help our clients maintain the technical condition of equipment at a safe level for operation and with the least-cost technology to improve production. In recent years, technical diagnostics has been particularly important for many areas of the industry due to the fact that, with process equipment aging, the way of maintaining reliable and efficient equipment operation with limited investments is a shift from the traditional system of operation to condition-oriented operation, providing savings of employment, production and energy resources upon implementation. The new technology of condition-oriented operation suggests optimization of equipment maintenance and control of technological process based on actual condition data and characteristics of each particular piece of equipment, as well as data on changes over time. In these circumstances, repairs and components technical condition restoration activities during operation are carried out not by regulatory deadlines, but as needed. ETC CKBN, LTD offers a professional approach and complete solution for examination of industrial safety, repair and modernization of technological equipment, as well as modern technological equipment supplies. Purpose 1
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The main activities 1. Industrial safety examination. Technical diagnostics and examination of industrial safety of technological equipment and pipelines, including transfer pipelines Project documentation examination Process equipment certification 2. Equipment modernization and repairs. Investigation and evaluation of equipment effectiveness Technical documentation development Manufacturing, supply and installation of upgrades and repairs Repair of equipment on operation site or in the factory Conducting technology equipment testing in design conditions Service maintenance of equipment 3. Design and delivery of process equipment. Development of new types of equipment with regard to the latest developments and requirements of industrial safety. Development of projects to bring the existing manufacturing equipment to meet the existing norms and rules (such as instrumentation and controls) Manufacturing, supply and supervision of equipment installation Commissioning and setting equipment to the mode. 4. Data collection and analysis. Creation of an equipment database Development of regulatory and technical documentation The main activities 3
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Laboratory for non-destructive testing (NDT), technical diagnostics (TD), physical metallurgy (PM) and welding (W) The laboratory for NDT, TD, PM and W is a structural subdivision of ETC CKBN, LTD, which carries out work on non-destructive testing and technical diagnostics of process equipment. The objectives of the laboratory include comprehensive work on non-destructive testing, technical diagnostics and examination of technical devices. Types of work for non-destructive testing: visual measurement control (VMC); ultrasound monitoring of welded joints and base metal, ultrasound control of continuity of metal (UC), ultrasound thickness gauging (UTG); control of surface defects with penetrating substances and magnetical-powder defect detection (PSC, MPD); Eddy current testing (EC); vibration diagnostic equipment (VD); thermal equipment control (TC); geodetic measurements of structures and components; determination of metal s chemical composition; metallographic studies (including field metallography); evaluation of mechanical properties of the base metal and welded joints (mechanical tests hardness testing); conducting corrosion studies; determination of strain-stress distribution of pipelines and structures; hydraulic (pneumatic) testing, accompanied by acoustic emission control. acoustic emission control (AEC); metal magnetic memory control method (MMC). The instrumentation pool of the laboratory is equipped in accordance with the tasks. Constant renewal and updating, verification and calibration of the instrumentation pool increases the quality of the works. The laboratory archive provides the necessary regulatory documents, specialized technical literature, records. With a balanced team consisting of experienced professionals and young staff, the laboratory carries out its work with the proper quality and in a timely manner. Laboratory for NDT, TD, PM and W 5
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Gazprom trusts us Expert Technical Center CKBN, LTD is a specialized technical point of OAO Gazprom for technical expertise to diagnose and extend the life of technological equipment of OAO Gazprom on gas, gas condensate, and oil processing (Order No. 128 of 17 June 2003). The organization has extensive experience, required equipment and permits, licenses, approvals, highly skilled professionals, qualified in examination of industrial safety in many industries, as evidenced by the Russian and European certificates and permits allowing for complex solving of technical issues arising from the examination (repairs, change of technology, modernization, etc.). All works are carried out in any climate conditions, in the shortest time and with proper quality. The works are carried out in close cooperation with the Russian Federal Service for Ecological, Technical and Atomic Supervision (RosTekhNadzor). The instrumentation pool of the company is constantly updated with new types of devices to carry out works in accordance with the requirements of regulatory and technical documentation. In addition, the organization has its own car park, allowing for mobile works in various regions of out country. Gazprom trusts us 7
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Our Partners LLC Gazprom dobycha Astrakhan LLC Gazprom transgaz Ufa LLC Gazprom transgaz Volgograd LLC Kavkaztransgaz LLC Krasnodarneftegaz LLC Kubangazprom LLC Gazprom transgaz St. Petersburg LLC Lukoil-Western Siberia LLC «Gazprom transgaz Moscow» LLC Gazprom dobycha Nadym LLC Gazprom transgaz Samara LLC Gazprom transgaz Ukhta LLC «Gazprom Pererabotka» LLC «Gazprom transgaz Yugorsk LLC Gazprom dobycha Urengoy LLC Gazprom transgaz Saratov LLC Gazprom dobycha Yamburg Rexam Beverage Can Naro-Fominsk, LTD LLC Noyabrsk Gas Complex LLC Sibur TyumenGaz LLC Plastic JSC Sibur Holding OAO NK Rosneft Oil and Gas Industry Companies of the Republic of Uzbekistan. Our Partners 9
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Experience On the whole, during the period from 2002 to 2007 ETC CKBN, LTD surveyed more than 3500 units of processing equipment, 97 km of technological pipelines, more than 600 km of transfer gas pipelines, 87 gas distribution stations and units, more than 30 units of pump-and-compressor equipment. A repair and upgrade of more than 100 units of various processing equipment has been completed. The volume of technical diagnostics works performed Number of equipment units examined Experience Years 11
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Industrial Safety Examination Technical diagnostics and examination of industrial safety of technological equipment and pipelines, including transfer pipelines Examination of project documentation Certification of process equipment Industrial equipment safety examination works are complex and generally include: 1. Technical documentation analysis; 2. External and internal examination, visual and measurement device control; 3. Installed automation systems control; 4. Non-destructive quality control of welded joints, thickness gauging, metal continuity control, control of surface defects; 5. Determination of chemical composition, metallographic studies, evaluation of mechanical properties of the base metal and welded joints; 6. Conducting of a comprehensive technical investigation and electrometric diagnosis (for transfer pipelines); 7. Conducting corrosive examination; 8. Analysis of technical diagnostics results and calculation of strength values; 9. Analysis of damage and technical condition parameters of the device, and establishing criteria for the limit state; 10. Implementation of refined calculations of strength values (including the method of finite elements); 11. Engineering calculations; 12. Determination of residual life of machinery; hydraulic (pneumatic, accompanied by acoustic-emission control) tests. In addition, our organization performs the following types of works for our Customers' convenience: 1. Preparation of process equipment for technical diagnostics: Probing Dismantling of facility coating Mechanical cleaning of welded joints 2. Issue of Recommendations on identified faults and inconsistencies of the actual equipment condition with the requirements of the current technical documentation. 3. Carrying out repairs of various natures and complexity levels. Industrial Safety Examination 13
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Equipment modernization and repair Examination and evaluation of equipment operation effectiveness Development of technical documentation Manufacturing, supply and installation of upgrades and repairs Equipment repairs on the operation site or in the factory Technological equipment tests in design conditions Equipment service maintenance When upgrading, one of the most important factors is the technical condition of the unit body-frame. To accurately determine it, the information gained through the examination of industrial safety of the device is used. From these data, upon analysis and strength calculations, the unit's body-frame factor of safety can be evaluated, and thus it becomes possible to assess the feasibility of upgrading each piece of equipment. Equipment modernization and repair 15
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Equipment modernization and repair ETC CKBN, LTD uses an integrated approach to the issue of the above-mentioned works, and offers to solve the problem with regard to the existing technology at the facility, rather than treating the device in isolation from the overall process. A good example of such works is to upgrade equipment BCS-2 (booster compressor station) of North Stavropolski UGS (underground gas storage), LLC Kavkaztransgaz. Namely, to ensure the quality requirements for gas preparation in accordance with OST 51-40-93 with the lowest capital costs, the following actions have been performed: - Upgrading 1st level separators to increase the efficiency of gas purification from mechanical impurities and dropping liquid. - Modernization of gas drying absorbers in order to obtain the necessary TTR and to reduce the loss of absorbent in the drained gas. - Upgrading of DEG regeneration columns in order to stabilize their work and to obtain the necessary concentration of glycol dehydration. Following the works and equipment warm-up, the TTR mode reached values between -12 and -17 C, the loss of glycol was less than 15 mg/m3, the concentration of DEG up to 99 wt. %, the loss of dropping liquid from the separators no more than 10 mg/m3. Thus, the illustrative example shows that in terms of economy of material and financial resources, modernization of production equipment is one of the most important ways to increase productivity and improve the quality of the product. Modernization of GDP-9 (gas-distributing point) separators Stavropolski UGS (Underground Gas Storage) The upgrade has enhanced the effectiveness of treatment from 70 to 99 % and increased the productivity of gas by 20 %. Equipment modernization and repair Modernization of GDP-9 (gas-distributing point) separators Stavropolski UGS (Underground Gas Before After The upgrade has enhanced the effectiveness of treatment from 70 to 99 % and increased the productivity of gas by 20 % 17
Process flow diagram of installation of absorption gas dehydration Process flow diagrams of new types of absorbers 18
Design and supply of process equipment Development of new types of equipment with regard to the latest developments and requirements of industrial safety. Development of projects to bring existing manufacturing equipment to the rules and regulations (such as instrumentation and controls). Production, supply and supervision of equipment installation Commissioning and setting equipment to the mode. The company's specialists have extensive experience in designing equipment for oil and gas industry, for example: Installations for complex natural gas and gas condensate conditioning (INGC and IGCC) on fisheries and UGS Installations for oil and associated gas field conditioning Installations for purification and processing of natural and associated gas in the GPPs (gas processing plants) Installations for processing of liquid hydrocarbons to obtain utilities and motor fuel, baseline components for petroleum chemistry Installations for preparation and processing of natural and associated gas, condensate and oil at offshore platforms and onshore facilities Installations for process gas purification and start-up gas treatment on CS and BCS (booster compression station) Installations for measurement and accounting of gas Complex equipment for flare installations Mass-transfer equipment (columns with different types of plates and nozzles) Heat exchangers Pressurized vessels: drainage, surface and underground Gas separators Oil separators Fluid degassers Filters for coarse and fine purification of liquids from solids Dust separators, filter separators, filter dust separators Separators of two-phase liquids Stoves and fired gas and oil heaters with direct heating and with intermediate heat medium Fired evaporators for regeneration of absorbents Fast closures of detachable device connections Quick change orifices for installation of measuring pipeline diaphragms Process blocks with the use of the above products, armature blocks, blocks of pumps and other equipment Design and supply of process equipment 19
20 Automated information database of OAO Gazprom for SUGS process equipment
Data collection and analysis Equipment database creation Development of regulatory and technical documentation At the customer's request our company develops a database of process equipment. Such databases are used in planning of industrial safety examinations, repairs or maintenance. Currently, the database is developed for gas facilities of OAO Gazprom and gas storage facilities. Data collection and analysis 21
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Development of regulatory and technical documentation Developed documents: - Methods of evaluation of residual life of vessels (dust separators, filters, separators, etc.) operating under pressure on CS and BCS of RAO Gazprom - RD 26.260.16-2002 Expert technical diagnostics of vessels and devices operating under pressure at the sites of production and processing of gas, gas condensate, oil in northern Russia, and underground storage facilities - WRD 39-1.10-066-2002 Expert technical diagnostics of vessels operating under pressure at compressor and gas-distributing stations - STO Gazprom 025-2006 Provision on expert technical diagnostics of tube shell heat exchangers - STO Gazprom 026-2006 Provision on expert technical diagnostics of process fired heater furnaces - STO 00220575.063-2005 Vessels, devices and process installation units for treatment and refinement of oil and gas containing hydrogen sulfide and causing corrosion cracking. Specifications Documents under development: - STO Gazprom Technical requirements for design, construction and operation of process equipment of column and capacitive types with a design lifetime of up to 40 years operating in non-aggressive environments - STO Gazprom Assembly, welding, heat treatment and quality control during repair and modernization of technological equipment of OAO Gazprom - STO Gazprom RD «Technical diagnostics of pressure vessels at the sites of OAO Gazprom Thus, ETC CKBN, LTD provides a full range of services from design and supply of process equipment, to examination of industrial safety and modernization of existing productions. Development of regulatory and technical documentation 23
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Thus, ETC CKBN, LTD provides a full range of services from design and supply of process equipment, to examination of industrial safety and modernization of existing productions. ETC CKBN, LTD management: ETC CKBN, LTD management Director General Oleg Anatolyevich Priymak First Deputy Director General - Chief Engineer Sergey Mikhaylovich Zyrianov 25
Geography of cooperation Contacts: 31 B.Serpuhovskaya Street Podolsk Moscow Region Russia 142100 RU Tel: +7(495) 542-33-19 +7(4967) 57-16-10 Tel/Fax: +7(4967) 68-16-40 E-mail: Info@etckbn.ru