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Com

pany

Vol

. 02

OUR TOP PROJECTS

01

TOP

PROJ

ECTS

AL

PHAB

ETIC

AL

ORDE

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A-H

THE ATYRAU REFINERY IS THE OLDEST PETROLEUM REFINING PLANT IN KAZAKHSTAN, BUILT MORE THAN 60 YEARS AGO.

THE RECONSTRUCTION OF THE REFINERY STARTED IN MARCH 2003, AS PART OF THE TURNKEY CONTRACT, WHICH WAS

WON TO JGC CORPORATION AS MAIN CONTRACTOR, IN COOPERATION WITH MARUBENI CORPORATION. THE SCOPE OF

THE PROJECT WAS TO PRODUCE OIL PRODUCTS THAT FULFILL MODERN STANDARDS AND ECOLOGICAL REQUIREMENTS.

THE TOTAL PROCESSING CAPACITY OF THE REFINERY IS OF 4.3 MILLION TONS OF OIL PER YEAR.

ATYRAU REFINERY / KAZAKHSTAN ONSHORE

EPC CONTRACTOR: JGC CORPORATION / END USER: KAZMUNAIGAS

KAZAKHSTAN

Caspian Sea

Uzbekistan

Kyrgyzstan

The project proved to be a success thanks both to the expe-

rience acquired by Skema in the Kazakh market since 1998,

which it was able to leverage fully, and to the important

technology transfer program established in Kazakhstan.

The commissioning was carried out by local electri-

cal engineers, under the supervision of Skema’s site

services manager.

SOLUTIONS DELIVERED

SKEMA WAS RESPONSIBLE FOR THE PROVISION OF THE PMCC SWITCHBOARDS FOR THE ATYRAU REFINERY.

INTELLIGENT MOTOR CONTROL CENTERS (57 COLUMNS, 371 DRAWERS)

POWER CENTERS (32 COLUMNS)

EPC CONTRACTOR: JGC CORPORATION / END USER: KAZMUNAIGAS

AWA PALOUKOU PLATFORM / CONGO OFFSHORE

EPC CONTRACTOR: SAIPEM / END USER: ENI CONGO

SAIPEM WAS AWARDED THE CONTRACT FOR THE ENGINEERING, PROCUREMENT, CONSTRUCTION AND INSTALLATION OF

A PLATFORM AND ASSOCIATED PIPELINES FOR THE DEVELOPMENT OF THE AWA PALOUKOU FIELD, LOCATED OFF THE

COAST OF THE REPUBLIC OF CONGO IN 2,730 FEET (832 M) OF WATER. THIS IS THE SECOND DEEPEST WATER DEPTH

FIXED PLATFORM PROJECT IN THE WORLD.

CONGO

Gabon

Angola

Democratic Republic of the Congo

Skema was responsible for the design, engineering, manufac-

turing, testing and commissioning of the MV and LV Switch-

gear, the RTUs and the IPCS System. A dual-redundant Local

Control Unit (LCU), based on redundant PLCs, is installed in

the Normal Electrical Room. This LCU is connected, via a re-

dundant Modbus on multimode fiber optic, to a Remote Con-

trol Unit (RCU) installed in the Emergency Electrical Room. The

LCU communicates, via redundant Ethernet network on mul-

timode fiber optic, with an Industrial PC installed in the Main

Electrical Room.

SOLUTIONS DELIVERED

MV SWITCHGEAR (11 COLUMNS)

INTELLIGENT POWER MOTOR CONTROL CENTERS (28 COLUMNS, 149 DRAWERS)

4 REMOTE TERMINAL UNITS

INTEGRATED PROTECTION AND CONTROL SYSTEM

EPC CONTRACTOR: SAIPEM / END USER: ENI CONGO

BAKU TBILISI CEYHAN PIPELINE / AZERBAIJAN AND GEORGIA ONSHORE

EPC CONTRACTOR: PETROFAC / END USER: BRITISH PETROLEUM

THE BAKU-TBILISI-CEYHAN PIPELINE TRANSPORTS CRUDE 1,760 KM (1,094 MILES) FROM THE AZERI-CHIRAG-GUNESH-

LI OIL FIELD IN THE CASPIAN SEA TO THE MEDITERRANEAN SEA. IT PASSES THROUGH BAKU, THE CAPITAL OF AZERBAI-

JAN; TBILISI, THE CAPITAL OF GEORGIA; AND CEYHAN, A PORT ON THE SOUTH-EASTERN MEDITERRANEAN COAST OF

TURKEY, HENCE ITS NAME. IT IS THE SECOND LONGEST OIL PIPELINE IN THE WORLD AND ONE OF THE BIGGEST ENGI-

NEERING PROJECTS.

GEORGIA

AZERBAIJAN

Caspian SeaBlack Sea

Turkey

IranIraq

Syria

Skema supplied Switchgear for Pump stations PS-G2

and PS-G1 and for the intermediate Pigging IP-A1 of the

Baku Tbilisi Ceyhan pipeline, and was responsible for the

design, engineering, manufacturing, testing and com-

missioning of PMCC type LV Switchgear and Bus Ducts.

SOLUTIONS DELIVERED


3 DC PANELS

BUS DUCTS

EPC CONTRACTOR: PETROFAC / END USER: BRITISH PETROLEUM

“All in all the Skema service was very satisfactory.”

Contracts Administrator

CHILEAN LNG / CHILE ONSHORE

THE CHILEAN LNG PROJECT CONSISTS OF A NEW GRASS-ROOTS LNG RECEIVING TERMINAL LOCATED AT QUINTERO BAY, AP-

PROXIMATELY 160 KM NORTHWEST OF SANTIAGO, CHILE. LNG CARRIER SHIPS UNLOAD AT A NEW JETTY BUILT AT QUINTERO,

INTO TWO STORAGE TANKS. PROCESS FACILITIES ARE INSTALLED TO ENABLE THE LNG TO BE PUMPED FROM THE STORAGE

TANKS, VAPORIZED AND EXPORTED INTO THE EXISTING TRANSMISSION SYSTEM VIA A NEW PIPELINE. THE TERMINAL IS EXPECT-

ED TO MEET 40% OF CHILEAN GAS DEMAND, WITH AN OVERALL ANNUAL SUPPLY CAPACITY OF 2.5 MILLION TONNES OF LNG.

EPC CONTRACTOR: CB&I / END USER: GNL QUINTERO / A JV BETWEEN: BRITISH GAS / ENDESA CHILE / ENAP / METROGAS

CHILEArgentina

South Pacific Ocean

Paraguay

Uruguay

Skema’s PMCCs were compliant with the following

seismic loads:

> Peak Horizontal Ground Acceleration: 0.83 g

> Peak Vertical Ground Acceleration: 0.59 g

> Seismic Design Code: ASCE 7/IBC 2000

The robustness of the structures was tested in relation to:

> Resistance and stability for individual modules and

for the various configurations

> Ground anchors

> Links between modules (bolts)

> Internal links to modules (rivets)

In addition, Skema’s Switchgear was successfully tested

for seismic load to IEC 60068-3-3 (1 g).

SOLUTIONS DELIVERED


5 INTERFACE PANELS

4 POWER TRANSFORMERS

EPC CONTRACTOR: CB&I / END USER: GNL QUINTERO / A JV BETWEEN: BRITISH GAS / ENDESA CHILE / ENAP / METROGAS

CHINAREVSKOYEFIELD / KAZAKHSTAN ONSHORE

EPC CONTRACTOR: EXTERRAN-BELLELI ENERGY / END USER: ZHAIKHMUNAI

CHINAREVSKOYE FIELD, APPROXIMATELY 324 SQUARE KILOMETERS IN SIZE, IS SITUATED CLOSE TO THE CITY OF URALSK

IN WEST KAZAKHSTAN AND IS ONLY 60 KM FROM THE BORDER WITH THE RUSSIAN FEDERATION. THE FIELD CONSISTS

OF AN OIL PROCESSING FACILITY CAPABLE OF PROCESSING 400,000 TPA OF CRUDE OIL, MULTIPLE OIL GATHERING AND

TRANSPORTATION LINES, A GAS POWERED ELECTRICITY GENERATION SYSTEM, MAJOR WAREHOUSE FACILITIES FOR THE

STORAGE OF OIL, MATERIALS, MACHINERY AND CHEMICALS USED IN CRUDE OIL PRODUCTION, AN EMPLOYEE FIELD CAMP

FOR 180 PEOPLE AS WELL AS 14 EXISTING WELLS AND 4 EXPLORATION WELLS UNDER DRILLING AND TEST OPERATIONS.

KAZAKHSTAN

Caspian SeaUzbekistan

Kyrgyzstan

Skema’s solution included the design, engineering, man-

ufacturing, testing and commissioning of MV and LV

Switchgear, including capacitor panels.

SOLUTIONS DELIVERED

MV 6 KV SWITCHGEAR (31 COLUMNS)


CAPACITOR PANELS

EPC CONTRACTOR: EXTERRAN-BELLELI ENERGY / END USER: ZHAIKHMUNAI

CORINTH REFINERY / GREECE ONSHORE

EPC CONTRACTOR: TECHNIP / END USER: MOTOR OIL HELLAS

THE CORINTH REFINERY WITH ITS ANCILLARY PLANTS AND OFFSITE FACILITIES IS CONSIDERED AS ONE OF THE MOST

MODERN REFINERIES IN EUROPE. DUE TO ITS FLEXIBILITY IT CAN PROCESS CRUDE OILS OF VARIOUS CHARACTERISTICS

AND PRODUCE A FULL RANGE OF PETROLEUM PRODUCTS, COMPLYING WITH THE MOST STRINGENT INTERNATIONAL

SPECIFICATIONS, SERVING MAJOR PETROLEUM MARKETING COMPANIES IN GREECE AND ABROAD. THE REFINERY PRO-

DUCTION OPERATIONS ARE LOCATED IN AGII THEODORI, IN THE PROVINCE OF CORINTH, ABOUT 70 KM OUTSIDE ATHENS.

GREECETurkey

Bulgaria

Romania

Albania

Black Sea

Skema was awarded the contract for the design, engi-

neering, manufacturing and installation of LV Switchgear

for the new Crude Distillation Unit Complex of the refinery.

SOLUTIONS DELIVERED

POWER MOTOR CONTROL CENTERS (53 COLUMNS, 188 DRAWERS)

DISTRIBUTION PANELS

BUS DUCTS

POWER FACTOR CORRECTION SYSTEM

EPC CONTRACTOR: TECHNIP / END USER: MOTOR OIL HELLAS

CONGO

Gabon

Angola

Democratic Republic of the Congo

DJENO POWER GENERATION PLANT / CONGO ONSHORE

EPC CONTRACTOR: RENCO / END USER: ENI CONGO

THE THERMOELECTRIC POWER PLANT IN DJENO, NEAR POINT NOIR IN CONGO, HAS A 25 MEGAWATT POWER CAPACITY.

THE POWER PLANT IS FIRED WITH ASSOCIATED GAS FROM THE OFFSHORE PLANTS OF KITINA, DJAMBALA AND FOUKAN-

DA, LOCATED 65 KM FROM THE COAST AND PRODUCING A TOTAL OF 26,000 BARRELS OF OIL PER DAY. GAS IS SEPA-

RATED ONSHORE AT THE DJENO TERMINAL CLOSE TO THE NEW POWER PLANT. THE PROJECT REPRESENTS THE FIRST

EXAMPLE OF USE AND EXPLOITATION OF ASSOCIATED GAS OTHERWISE FLARED. THE PROJECT AIMS AT REDUCING GAS

FLARING AND AT USING IT IN POWER GENERATION WITH SIGNIFICANT SOCIAL, ECONOMIC AND ENVIRONMENTAL BENEFITS.

Skema was responsible for the design, engineering, man-

ufacturing, supply, inspection, testing, export packing and

supervision of onsite commissioning of LV Switchgear

and Intelligent Motor Control Centers.

SOLUTIONS DELIVERED

MOTOR CONTROL CENTERS (12 COLUMNS, 19 DRAWERS)


AUXILIARY SERVICES SWITCHBOARDS

EPC CONTRACTOR: RENCO / END USER: ENI CONGO

NIGERIA

Camerun

NigerCiad

EBOCHA OIL CENTER / NIGERIA ONSHORE

THE EBOCHA OIL CENTRE (EOC) IS LOCATED IN THE NAOC LAND AREA, APPROXIMATELY 10 KM FROM THE OB/OB GAS

PLANT IN THE OBRIKOM RIVER STATE, NIGERIA. THE EBOCHA OIL CENTRE COLLECTS THE LIQUID PRODUCTION FROM IRRI,

KWALE, AKRI, OB/OB AND ADDAX AND TRANSFERS IT TO THE BRASS TERMINAL.

EPC CONTRACTOR: SUDELETTRA NIGERIA / END USER: NAOC

The Power Motor Control Centers supplied for the project

were equipped with automatic change-over to allow the in-

plant distribution of power supply coming from two main

transformers and two emergency diesel generators. The

capacitor banks were required for automatic regulation of

the electrical network power factor.

EPC CONTRACTOR: SUDELETTRA NIGERIA / END USER: NAOC

SOLUTIONS DELIVERED

POWER CENTER (20 COLUMNS)

MOTOR CONTROL CENTERS (16 COLUMNS)

LV CAPACITOR BANKS (4 COLUMNS)

KAZAKHSTAN

Caspian Sea

Uzbekistan

Kyrgyzstan

ESKENE WEST RAIL / KAZAKHSTAN ONSHORE

EPC CONTRACTOR: WORLEYPARSONS / END USER: NORTH CASPIAN OPERATING COMPANY (NCOC) / A CONSORTIUM OF KAZMUNAIGAZ / ENI / SHELL / EXXONMOBIL / TOTAL / CNPC / INPEX

ESKENE WEST RAIL CONSISTS OF THREE BASIC FACILITIES LINKED BY A COMMON RAIL SYSTEM THAT REQUIRE UPGRAD-

ING WORKS TO ACCOMMODATE THE INCREASED RAIL TRAFFIC FROM THE RAIL LOADING FACILITIES (RLF) AND THE MAR-

SHALLING YARD (MYD). THE ESKENE WEST RAIL SERVES THE KASHAGAN FIELD.

Skema was awarded the contract for the design, engineering,

manufacturing and testing of the whole electrical package

for the Eskene West Rail project, encompassing everything

from the Intelligent LV and MV Switchgear to the Modular

Substations.

SOLUTIONS DELIVERED

2 MODULAR SUBSTATIONS

MV 10 KV SWITCHGEAR (41 COLUMNS)


9 REMOTE TERMINAL UNITS

DISTRIBUTION BOARDS (87 COLUMNS)

EPC CONTRACTOR: WORLEYPARSONS / END USER: NORTH CASPIAN OPERATING COMPANY (NCOC) / A CONSORTIUM OF KAZMUNAIGAZ / ENI / SHELL / EXXONMOBIL / TOTAL / CNPC / INPEX

FLARES MODIFICATION DAS ISLAND / UAEONSHORE

EPC CONTRACTOR: TECHNIP / END USER: ADMA-OPCO

ADGAS OFFSHORE ASSOCIATED GAS (OAG) PLANT AND INTEGRATED GAS DEVELOPMENT (IGD) FACILITY ARE ON THE

NORTH WEST SIDE OF DAS ISLAND, WHICH IS ADJACENT TO ADMA-OPCO FLARE AREA. THE FLARES POSE RADIATION

HAZARD AND A HIGH RISK OF TOXIC GAS (H2S) EXPOSURE DURING CONSTRUCTION, OPERATION AND MAINTENANCE

PHASES OF THE PROJECT IN CASE OF FLAME OUT FROM THE FINGER FLARES DUE TO THEIR CLOSE PROXIMITY TO THE

OAG AND IGD FACILITIES. ADMA-OPCO HAS CONDUCTED STUDIES TO IMPLEMENT MODIFICATION AND NEW INSTALLA-

TIONS TO MITIGATE THE ABOVE.

IranIraq

Saudi Arabia

Oman

UAEQatar

Kuwait

EPC CONTRACTOR: TECHNIP / END USER: ADMA-OPCO

The degree of protection of the Switchgear is IP 42,

Form 4b, and the structure is equipped with 400 mm-

wide double doors in the cable compartment to facili-

tate access to and the connection of power and auxil-

iary cables to the dedicated feeder.

Color coded insulating caps are provided for all copper

bars and relevant connections. Solutions are provided

to prevent arc propagation across bus-sections using

fire-retardant materials.

Distribution busbar safety shutters have padlock facil-

ities in their closed position. Local and remote selec-

tor switches are padlockable in either position to avoid

unauthorized operation. All motor starters have oper-

ation counters.

SOLUTIONS DELIVERED

SKEMA WAS AWARDED THE CONTRACT FOR THE DESIGN, ENGINEERING, MANUFACTURING, INSPECTION AND TESTING OF:


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

“This was a technically challenging order. As a result Skema worked very collaboratively with our engineering and management team to

come to successful solutions.”

Project Manager

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

ENGINEERING

The substations supplied for the FGP/

WPMP project are one level steel

structures installed above a concrete

foundation. The main structure con-

sists of transverse frames connected

by floor beams, wall corrugated plates

and floor plates. The main structure is

completed with longitudinal beams

connecting the bottom of the main

columns. The structures and machin-

ery are designed to withstand the

seismic design loads and to meet the

general seismic requirements, in ac-

cordance with the SiD (Safety in De-

sign) requirements. All analyses were

carried out using Semi-probabilistic

method at Limit states (LSD), while all

structures were analyzed using FEM

method bend on the package 3D

model, considering the operation con-

figuration and the lifting phase.

For seismic analysis static analysis

was carried out. The lifting was from

top of the substation.

A 3D separate model was generated

for each module in a right handed or-

thogonal Cartesian coordinate sys-

tem. The structural models of the

modules were representative of the

actual structural components and in-

cluded all primary framing members,

namely columns, f loor beams and

floor plates.

FABRICATION IN ITALY

The modular substations fabricated in

Italy were tested at Skema’s yard fa-

cilities, then disassembled in modules

and transported by road to Tengiz, to

be reassembled locally.

The supply included 10 Container-

ized complete transformer 10/0.4 kV

substations for the Contractors’ Com-

pound / Early Works, equipped with:

> 10 kV Gas Insulated Switchgear

(6 sections)

> 10 kV Ring Main units (24 sections)

> Intelligent PMCCs

(66 sections, 154 drawers)

> Distribution Boards (68 sections)

> 220 VDC system

> 220 VDC Ni-Cd battery rack

> 10/0.4 kV cast resin Transformers

> Lighting and electrical system

> HVAC system

> Fire and gas system

2 Containerized 35/10 kV packaged

substations were fabricated for New

Camp 9/A, and were equipped with:


(21 sections)


(26 sections)

> 10 kV Disconnector Switches

(4 sections)


> 220 VDC system


> 10/0.4 kV – 750 kVA cast resin

Transformers

> On Load Tap Changer (OLTC) panel

> Patch panel

> Badge reader access door


> HVAC system


The equipment was pre-assembled

and base plated mounted to the maxi-

mum extent including piping, supports,

instruments, wiring, junction boxes.

FABRICATION IN KAZAKHSTAN

Skema LLP was awarded the local fab-

rication of 1 Containerized 10 kV pack-

aged substation for the Construction

Compound. The substation included:


(15 sections)


> 220 VDC system


> Cast resin Transformers 35/0.4 kV


> HVAC system


The equipment was pre-assembled

and base plated mounted to the maxi-

mum extent including piping, supports,

instruments, wiring, junction boxes.

The modular substation fabricated

in Atyrau was tested at the fabrica-

tion yard facilities, then disassembled

in modules and transported by road

to Tengiz, to be reassembled locally.

For the modular substations fabricated

for the FGP/WPMP, Skema supplied the

following services: preservation, pro-

tection and storage at the fabrication

yard; disassembly in modules; pack-

aging, preservation and protection for

sea and land transport; winterization

for shipment and storage; load out.

“I would like to thank you and your team for producing a quality product which will serve TCO for many years. I appreciate your effort, patience and understanding in working with us to achieve this significant milestone of

signing off the substations for T9A and Orken Village to the required standard

and to the agreed schedule.”

Lead Project Engineer

Skema was in charge of the sizing, detailed design, engi-

neering, project management, scheduling, procurement,

fabrication, painting, inspection, non-destructive exam-

ination, shop testing, expediting, QA/HSE management,

documentation and preservation of 13 Modular Substa-

tions. The fabrication, multidisciplinary installation ac-

tivities (architectural, mechanical, E&I, HVAC, etc.), test-

ing and pre-commissioning of 12 modular substations

were carried out at Skema’s yard in Ravenna, Italy, while

1 modular substation was fabricated by Skema LLP in

Kazakhstan. Performance was according to IEC/GOST

standards and PUE ROK.

SOLUTIONS DELIVERED

13 MODULAR SUBSTATIONS

MV 10/35 KV SWITCHGEAR (68 COLUMNS)

MV 10 KV RING MAIN UNITS (24 COLUMNS)




KAZAKHSTAN

Caspian Sea

Uzbekistan

Kyrgyzstan

DISCOVERED IN 1979, TENGIZ IS ONE OF THE WORLD’S DEEPEST PRODUCING SUPER GIANT OILFIELDS AND ONE OF THE

LARGEST DISCOVERIES IN RECENT HISTORY. LOCATED IN A REMOTE AREA OF WESTERN KAZAKHSTAN, THE UNDERGROUND

TENGIZ RESERVOIR MEASURES 20 KILOMETRES BY 21 KILOMETRES. THE ENTIRE TENGIZ OILFIELD AREA IS ESTIMATED TO

CONTAIN 750 MILLION TO 1.1 BILLION METRIC TONNES (6 TO 9 BILLION BARRELS) OF RECOVERABLE OIL.



“I’d like to add my sincere thanks to you and your team for a great job completed on time thanks to all of your efforts, to an excellent quality

and with a good safety record. Thanks again.”

Project Engineer

SKEMA’S LV SWITCHGEAR/MCC’S

FOR CORE AND MAIN SUBSTATIONS

INTERNAL ARC FAULT PROTECTION

in accordance to the IEC TR 61641.

The mechanical protection of the switch-

gear was tested by extending the arc

duration to 0.5 s.

OPTICAL SENSORS for arc fault detection

on busbar systems and functional units.

Fiber optic sensors connected to the con-

trol system were installed along the main

and distribution busbar systems, to detect

arc fault. The system allows the electrical

protection activation in a very quick time,

preventing switchgear damages. Besides,

all the functional units are equipped with

a dedicated optic sensor to interrupt

any possible fault inside the drawers.

INFRARED SENSORS for monitoring

the temperature of the main busburs

of busbar junctions and cable entry

for incomers and power transformers.

The connection of the main busbar sys-

tem of the switchgear, the cable entry

sections of incomers and bus-ties, the

connection to the MV/LV power trans-

formers are monitored through a tem-

perature control infrared sensor sys-

tem. Should the connection between

busbars, or the connection of a power

cable loosen up, the temperature in-

crease detected by the sensor would

activate the alarm reporting system.

The consequent punctual control/

switching prevents the damages that

might arise from continued heating.

COMMUNICATION SYSTEM between

functional units and main control system

through Ethernet or optic fiber. All the

data collected from the functional units

and the monitoring data from the fiber

optic and infrared sensors are trans-

ferred via Ethernet, and then through

an optic fiber connection to the main

control system. This allows the unique

coordination of all the substation sys-

tems and utilities.

SUBSTATION PLC

The PLC is installed in the substations’

HVAC room and it is provided with a

touch screen HMI. The logic control sys-

tem is designed to command and control

the HVAC system, taking inputs from the

field instruments and sending outputs to

the equipment such as isolating damp-

ers, fans, air handling units and electric

heaters, as per the operating philosophy

and cause and effect matrix. The HVAC

PLC is also interfacing with F&G panel

and provides different operating modes

depending on the environmental and

emergency situations that may occur

during the normal system operations.


SOLUTIONS DELIVERED

LV SWITCHGEAR AND MOTOR CONTROL CENTERS (64 COLUMNS, 102 DRAWERS)


BUS DUCTS (4 LINES)

DRY TYPE CAST RESIN TRANSFORMERS (5 UNITS)

PLC PANELS (12 COLUMNS)

The LV switchgear solutions for the Core and Main Sub-

stations were designed and manufactured in compliance

with the stringent project requirements.

The project defined distinctive specifications for both the

mechanical structure of the switchgear, and the elec-

tric and electronic equipment of the functional units and

columns.

In particular, the LV switchgear are complete with au-

to-transfer scheme, momentary synchronizing between

incomers, switchgear and transformer protection, con-

trol and metering equipment, temperature monitoring

system and arc flash detection system.

“Great job Skema! Thank you very much for your hard work and dedication to complete this project with quality and collaboration.”

Senior Project Manager

KAZAKHSTAN

Caspian Sea

Uzbekistan

Kyrgyzstan









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:


(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.


KAZAKHSTAN

Caspian Sea

Uzbekistan

Kyrgyzstan









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

GE’s scope of supply included 110

kV Gas Insulated Switchgear with

the associated control panels, UPS

system and batteries.

“I really appreciate the whole Skema team, very professional service and delivered on their promises to make

the project a success.”

Project Engineer

LENGTH 81.1 M

HEIGHT 8.6 M

WEIGHT 1,097 T

WIDTH 14.6 M

SHIPPED IN 2 MODULES

“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 in 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 ManagerFGP Control & Power

THE MAIN SUBSTATION

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

Equipment Room on the first 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

maintenance.

Access ladders entrance, emergency

and maintenance service doors com-

plete the substation, and 3 remova-

ble panels ensure easy installation

and maintenance of the bigger and

heavier equipment. The substation

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, ensuring the connection

among the main equipment such

as GIS, transformers, switchgear,

lighting, small power and sensors from

the various rooms.

110 kV GIS AREA (GIS MODULE)

This module contains the gas insu-

lated switchgear (GIS). A 1.5 t bridge

crane is installed over the top floor

of the GIS area for switchgear mainte-

nance purposes.

ELECTRICAL ROOM (UTILITY

MODULE) – 3 transformers feeding

the LV switchgear, the UPS, and the

distribution boards are installed in the

electrical room, which also includes an

office and a restroom.

BATTERY ROOM (UTILITY MODULE)

The batteries are located on specific

racks in this room, which is equipped

with an eye wash facility and a trolley

to move the batteries.

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 also includes

2 chemical filters and 2 fans.

INSTRUMENT EQUIPMENT ROOM

(UTILITY MODULE) – This room is

designed to host control panels.

ENGINEERING AND SERVICES

A complete 3D computer model of the

structure was developed by Skema us-

ing a dedicated calculation software, to

perform the structural analysis for all

conditions applicable to the substation:

in-service, load out and transportation.

All analyses, which included the struc-

tural verifications of all welded and

bolted joints, were carried out consid-

ering the gravity loads of the structure

and equipment, combined with the

dynamic loads and environmental loads

applicable to each specific condition.

For the Main substation Skema sup-

plied the following services:

> Preservation, protection and

storage at the fabrication yard

> Packaging, preservation and pro-

tection for sea and land transport

> Winterization for shipment and

storage

> Load out.

The substation was prepared for load

out by removing all the external items

which were properly packed and fixed

inside the modules or shipped as loose

items inside standard containers.


SOLUTIONS DELIVERED

110 KV MAIN SUBSTATION

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

DIMENSIONS (M) 81.1 X 14.6 X 8.6 WEIGHT (T) 1,097

In consortium with GE Grid Solutions, Skema was award-

ed the contract for the design, engineering, development,

fabrication, electrical equipment, multidisciplinary instal-

lation activities, inspection, testing program, documen-

tation and preservation for shipment of the 110 kV Main

substation for the TCO FGP project. The Main substa-

tion, which is the largest substation of the overall Future

Growth Project, consists of 2 modules which were pre-

fabricated, assembled, sand-blasted, painted and bolted

to form a unique structure. The modules were then dis-

assembled and shipped to Kazakhstan by barge.

FPSO OSX2 / BRAZIL OFFSHORE

EPC CONTRACTOR: SBM OFFSHORE / END USER: OSX-GRUPO EBX

CAMPOS BASIN IS A PETROLEUM RICH AREA LOCATED OFFSHORE OF RIO DE JANEIRO. IT HAS A TOTAL AREA OF 100,000

SQUARE KILOMETERS. THE FPSO IS USED IN THE CAMPOS BASIN, BRAZIL, ON ONE OF A STRING OF HEAVY OILFIELDS

DISCOVERED BY OGX. THE OSX2 IS ABLE TO PRODUCE UP TO 100,000 BARRELS PER DAY OF OIL, WITH STORAGE CA-

PACITY FOR 1.3 MILLION BARRELS.

BRAZIL

Bolivia

Paraguay

SurinameGuyana French Guiana

The Switchgear supplied by Skema, with a rated current

of 5000 A and a rated short-time withstand current of

100 kA, complies with the most stringent requirements

for offshore marine applications: compact dimensions for

limited space, handles on the front of the Switchgear to

prevent injury to personnel in the event of sudden move-

ments, shock-resistant plinth.

Skema used the Bender system to monitor the electri-

cal network and to reveal defects and problems on the

network that could compromise the functionality of the

Switchgear.

SOLUTIONS DELIVERED

SKEMA WAS AWARDED THE CONTRACT FOR THE DESIGN, ENGINEERING, MANUFACTURING, INSPECTION AND TESTING OF:


EPC CONTRACTOR: SBM OFFSHORE / END USER: OSX-GRUPO EBX

EPC CONTRACTOR: CB&I / END USER: NEXEN PETROLEUM

DISCOVERED IN 2007, THE GOLDEN EAGLE AREA (WHICH IS MADE UP OF RESERVOIRS GOLDEN EAGLE, HOBBY AND PER-

EGRINE), IS LOCATED IN APPROXIMATELY 113 M WATER DEPTH IN THE UK SECTOR OF THE NORTH SEA 70 KM OFFSHORE

(19 KM NORTH OF THE BUZZARD FIELD, 21 KM NORTHWEST OF THE ETTRICK FIELD AND 4 KM SOUTH OF THE ATLANTIC

FIELD). THE FIELD IS DEVELOPED USING TWO PLATFORMS - A WELLHEAD PLATFORM AND A PRODUCTION, UTILITY AND

QUARTERS (PUQ) PLATFORM. THE TWO PLATFORMS ARE CONNECTED BY A 70 M BRIDGE. THE FACILITIES BEING BUILT AT

GOLDEN EAGLE CAN ACT AS A FUTURE HUB FOR TIEBACKS. OPERATOR NEXEN HAS ESTIMATED THE GOLDEN EAGLE AREA

CONTAINS 140-150 MILLION BARRELS OF OIL EQUIVALENT IN GROSS RECOVERABLE CONTINGENT RESOURCES, MAKING IT

ONE OF THE LARGEST OIL DISCOVERIES IN THE UK NORTH SEA IN RECENT YEARS.

GOLDEN EAGLE / NORTH SEA (UK) OFFSHORE


UNITEDKINGDOM

Ireland

France

Germany

SKEMA MOTOR CONTROL AND

MANAGEMENT SYSTEM (MCMS)

The Motor Control and Manage-

ment System (MCMS) developed for

the platforms integrates the intel-

ligent Motor Control Centers made

by Skema with the Process Control

System (PCS), the Power Manage-

ment System (PMS) and the Distribu-

tion Management System (DMS), and

enables an integrated and safe man-

agement of all the electrical users.

The integration is achieved thanks

to the communication capabil i-

ties of the DCUs which operate as

gateways between the upstream

PCS/PMS/DMS and the IEDs with-

in the downstream switchgear.

The DCUs allow concurrent commu-

nication via redundant Modubus-RTU

and OPC between the different sys-

tems. Such integration completely ex-

ploits the capabilities of the 400 IEDs

(supplied by different manufacturers)

which measure, protect and control

all the users connected to the MCMS.

Importantly, the MCMS not only helps

the operator to control the users, but

is of great significance to the electrical

engineer in verifying the performances

of the electrical networks by means of

continuous monitoring of the param-

eters set in the IEDs with special at-

tention to those which influence the

reliability/maintenance of the plant.

The MCMS records the running hours,

the number of operations of each feed-

er circuit and analyzes the most fre-

quent causes of tripping/alarms, so

that the engineer can plan proac-

tive counter measures to avoid future

plant problems which may cause eco-

nomic losses and, in the worst cas-

es, safety risks to the plant/personnel.

This type of intelligent reporting is

pivotal in ensuring a proactive and

cost effective maintenance regime of

the plant. All the DCUs components

are dual redundant and can survive

any individual component failure. The

serial links communicating with the

downstream IEDs via Modbus-RTU

ring (motor managers, measuring

devices and protection relays) can

survive a fault where the serial ca-

ble is broken between two devices.

System response times are of ut-

most importance, the MCMS is de-

signed for ultimate performance.

A command received from the PCS

is actuated by the IEDs in less than

100 ms and the change of status

is available to the PCS in less than

1 second. These performances are

achieved while the DCUs communi-

cate concurrently with the PCS via

Modbus-TCP, with the PMS via Mod-

bus-RTU and with the DMS via OPC.

The special features of Skema’s intelligent MCC pro-

duction cycle are: the focus on the client’s requirements

during the system design phase; the integrated supply

chain for the switchboard and the control system; the

painstaking attention to detail during the testing phase

(conducted entirely in house), which sees all of the sys-

tem functions being checked meticulously; and the FAT

procedure, which is carried out in partnership with the

client in a fully integrated environment.

All of this helps to guarantee that the system performs

to a very high standard, and that it will require very little

(if any) on-site work in order to commission the full system.


SOLUTIONS DELIVERED



DISTRIBUTION BOARDS

4 DUAL REDUNDANT DATA CONCENTRATOR UNITS (DCUS)

MOTOR CONTROL AND MANAGEMENT SYSTEM (MCMS)

UNITEDKINGDOM

Ireland

France

Germany

GRAIN LNG RTLF / ISLE OF GRAIN (UK) ONSHORE

EPC CONTRACTOR: CB&I / END USER: NATIONAL GRID

NATIONAL GRID GRAIN LNG, OPERATOR OF THE LARGEST LIQUEFIED NATURAL GAS (LNG) IMPORTATION TERMINAL IN EU-

ROPE, AWARDED CONTRACT FOR THE CONSTRUCTION OF NEW ROAD TANKER LOADING FACILITY. THE FACILITY CATERS

FOR THE COMMERCIAL, INDUSTRIAL AND ROAD FUEL MARKETS - COMPLEMENTING EXISTING SERVICES AT GRAIN LNG

TERMINAL ON THE ISLE OF GRAIN (KENT). THE CONSTRUCTION CONTRACT IS FOR AN INITIAL, TWO-BAY ROAD TANKER

LOADING FACILITY (RTLF), WITH THE OPTION TO EXPAND FURTHER SHOULD MARKET DEMAND REQUIRE IT.

EPC CONTRACTOR: CB&I / END USER: NATIONAL GRID

The Intelligent LV Switchgear supplied for the Grain LNG Pro-

ject complies with the most stringent requirements of the Oil

& Gas industry: internal-arc proof, IP42 external protection,

4b type 5 segregation form, IP4X internal protection, IP20

protection when a drawer has been removed from the as-

sembly, fully segregated busbar system, non-interchangea-

ble interlock system for drawers that are mechanically iden-

tical but electrically different.

SOLUTIONS DELIVERED

SKEMA WAS AWARDED THE CONTRACT FOR THE DESIGN, ENGINEERING, MANUFACTURING AND TESTING OF:


DISTRIBUTION BOARD (1 PANEL)

HANNIBAL SOUR GAS / TUNISIAONSHORE

EPC CONTRACTOR: WORLEYPARSONS / END USER: BG TUNISIA

THE HANNIBAL SOUR GAS PLANT LOCATED 20 KILOMETERS SOUTH OF SFAX PROCESSES THE HYDROCARBONS BROUGHT

ONSHORE FROM THE MISKAR GAS FIELD, LOCATED 125 KILOMETERS OFFSHORE IN THE GULF OF GABES, TUNISIA. THIS

FIELD IS 100% OPERATED BY BG TUNISIA. SOUR GAS FROM TEN WELLS IS SENT THROUGH A PIPELINE AND PROCESSED

AT THE HANNIBAL PLANT AND SUPPLIED TO THE SOCIÉTÉ TUNISIENNE DE L’ELECTRICITÉ ET DU GAZ (STEG), TUNISIA’S

STATE ELECTRICITY AND GAS COMPANY. DURING ITS LIFETIME, IT IS ESTIMATED THAT THE MISKAR FIELD WILL PRODUCE

MORE THAN 700 BILLION CUBIC FEET OF GAS.

TUNISIA

LybiaAlgeria

Morocco

EPC CONTRACTOR: WORLEYPARSONS / END USER: BG TUNISIA

The LER is composed of:

> Weather-tight enclosure and supporting structure

> Electrical equipment room

> Instrumentation equipment room

> Small power distribution within the building

> HVAC systems

> PA/GA loudspeaker system facilities

> Fire & Gas detection

> CO2 flood system

> PABX telephone system facilities

> Normal lighting system, including external door lighting

> Escape lighting system on emergency exits and routes

> Cable trays/racks

> Earthing system

> Portable fire extinguishers

SOLUTIONS DELIVERED

SKEMA WAS AWARDED THE CONTRACT FOR THE DETAILED DESIGN, SUPPLY AND INSTALLATION OF A PREFABRICATED METAL LOCAL EQUIPMENT ROOM (LER), FULLY ASSEMBLED, WIRED AND TESTED IN SKEMA’S FACTORY IN CESANO MADERNO, FOR INSTALLATION ON SITE.

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