Every year, Caspian Pipeline Consortium makes several scheduled shutdowns of the oil pipeline to do maintenance, repair and tie-in activities that are impossible to be done on an operating pipeline. During a shutdown of the Tengiz-Novorossiysk pipeline system scheduled for October 8-11, CPC personnel and contractors performed maintenance jobs on mechanical, process, power and electrical equipment, measurement instrumentation and control systems at pump station sites. Specialists checked operation of emergency shutdown and unit protection systems.
While the oil pipeline was depressurized, two large diameter ball valves were replaced at the Tengiz pump station, one at the Atyrau pump station, and another two large-diameter ball valves on a pig launcher/receiver at KP 204. Eight ball valves were replaced on the Astrakhan pump station meter and one large diameter ball valve on the KP 1031 pig launcher/receiver.
It is noteworthy that the ball valve pipeline replacement is being done by CPC as part of a long-term program. New equipment uses flanged and welded knockdown valves, which will allow to simplify the repair process looking forward and, if necessary, will allow to do repairs in the field using CPC maintenance contractor resources. Over 130 old-type ball valves have been replaced at CPC sites since 2012. Another almost 40 ball valves will be replaced in 2019-2020, including fulling replacing all valves in an oil quantity and quality measurement system at the Astrakhan pump station.
Two linepipe sections of the oil pipeline were repaired by means of a modern composite sleeve technology. Ball valve maintenance was completed, including seasonal work activities, integrity checks, opening/closing, electric drive and control system checks. As part of a surge relief program, specialists performed scheduled work to protect valves from unauthorized closing, including actuator coil power supply diagram change, installation of tested software and code in programmable logic controllers.
In total, about 185 contractor personnel and 67 special equipment unites were involved in work activities requiring pipeline integrity breach.
CPC management commended smooth coordination between CPC and contractor personnel, strict industrial safety compliance, and careful preparations. By now, crude oil transportation is resumed as per plan.
The CPC Pipeline System is one of the major investment projects in the energy sector with participation of foreign capital in the CIS. The length of the Tengiz–Novorossiysk Pipeline is 1,511 km; it transports over two thirds of all Kazakhstan export crude, as well as crude from Russian oil fields, including the Caspian Region. The CPC Marine Terminal is equipped with three Single Point Moorings (SPM) that allow to load tankers safely at a significant distance offshore, also amid poor weather conditions.
CPC Shareholders: Russian Federation (represented by Transneft – 24% and CPC Company – 7%) – 31%; Republic of Kazakhstan (represented by KazMunayGaz – 19% and Kazakhstan Pipeline Ventures LLC – 1.75%) – 20.75%; Chevron Caspian Pipeline Consortium Company – 15%; LUKARCO B.V. – 12,5%; Mobil Caspian Pipeline Company – 7,5%; Rosneft-Shell Caspian Ventures Limited – 7,5%; BG Overseas Holding Limited – 2%; Eni International N.A. N.V. – 2% и Oryx Caspian Pipeline LLC – 1.75%.