Polish oil and gas giant increases oil extraction thanks to innovative gas injection project

2017-05-11 - ABB has implemented the first in Poland excess gas injection project for PGNiG S.A., state-owned oil and natural gas company. The installation in “Debno” Oil and Natural Gas Mine in western Poland is expected to increase oil production by 10 percent, equal to 100 tons per day. The order is worth around $4 mln (16 mln PLN).

Fot. PGNiG SA


Barnówko-Mostno-Buszewo (BMB) is the largest natural gas and crude oil deposit in Poland. It allows for a daily extraction of 1000 tonnes of oil, 65 tonnes of LPG, a 1 million m3 of natural gas and 65 tonnes of liquid sulphur. After more than 20 years of exploitation, operator faced some significant problems. The extraction of crude oil directly influences the growth of gas production but the capacity of neighbouring gas processing facility in “Debno” is limited.

In order to increase the efficiency of oil extraction, in 2015 PGNiG S.A. decided to implement an innovative project of injecting excess natural gas back into the well. The investment was necessary since reduction of gas extraction on the exploration wells due to limited processing capabilities would simultaneously decrease crude oil extraction. This would have negative impact on PGNiG’s business operations.

The project assumes that re-injection of 200 nm3/min of excess gas will enable the increase of crude oil production by ca. 100 tonnes per day. ABB was the general contractor of the investment responsible for turnkey delivery, including construction of the 2.9 km long pipeline, design and construction works, as well as installation and commissioning of the sour gas compressor, power equipment and measurement & analytics. As a result, the customer received flexible and reliable solution that will drive complex operations safely and efficiently in difficult working conditions.

Building this innovative idea into a reality took two years. On top of technical challenges, installation and construction had to be performed under harsh environment conditions and with the surroundings filled with toxic gas contaminated by extremely high-pressure hydrogen sulphide.

“This project is an innovative investment in Poland. Not only was it unusual because of the rough environment of the existing mine complex, but also due to the prototype application of the compressor set, which necessitated the use of specific materials and equipment. In addition to improving production for the site – ensuring safety for both the people and the plant was top priority.” explains Sławomir Gorczynski, responsible for project execution in O&G business, ABB Poland.

The pipeline has been equipped with a rare acoustic leak detection system. Should there be any leak or pressure drop in the transmission pipelines, the application instantly informs of such leak and pinpoints its location. The compressor building is protected by gas and fire detection systems. Any irregularities in equipment operation are immediately diagnosed by the relevant protection systems, including taking proper actions to prevent any consequential effects (explosion, fire, leak).

It is another project which confirms the strong position of ABB in the Polish gas industry, as well as globally. Leveraging innovative technology to increase production and improve plant operations is the key that makes this all possible.

ABB (ABBN: SIX Swiss Ex) is a pioneering technology leader in electrification products, robotics and motion, industrial automation and power grids, serving customers in utilities, industry and transport & infrastructure globally. Continuing a more than 125-year history of innovation, ABB today is writing the future of industrial digitalization and driving the Energy and Fourth Industrial Revolutions. ABB operates in more than 100 countries with about 132,000 employees. www.abb.com

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