The task of gas compressor stations is to compress gas to such a pressure which allows to surmount the hydraulic resistance in a particular section of a pipeline at a given gas flow. The “heart” of compressor stations is composed of turbocompressor units. Each unit consists of a 2.3 million cubic m/h gas transmission compressor driven by a gas turbine with a thermal efficiency higher than 34%. Since gas compression causes its temperature to rise cooler fans are installed to cool the gas after it is compressed. This helps to increase the transmission capacity of the transit pipeline. 

The compressor stations consists of turbocompressor units, gas filters, gas coolers, power supply station with a backup generator, reduction and metering unit and auxiliary systems of inert gas, compressed air, fire control, heating, water supply and sewage and the remote control grid. The site will also accommodate the office building and control room. The compressor stations have their own water intakes and local power supply grid; access roads have also been upgraded. The site occupies approximately 11 hectares.

The compressor station is situated at the Terminal built along with the transit pipeline. Process gas within the compressor stations flows through DN1200-800 pipes equipped with remotely or manually controlled taps. The filter station consists of five independent vertical filters, four of which are operational and one is stand-by. Two of the three installed turbosets operate in parallel and one is stand-by. The parallel operation of turbosets, as well as load distribution and anti-pumping system of each gas compressor are automatically controlled. Behind gas compressors are installed cooler fans, eight sections each, where gas is cooled down to 30oC. The compressor stations are automatically controlled and there is a safety control system which will disable individual compressors or the whole station in case of any irregular operation, gas leakage or other hazards.

Compressor stations parameters can be fully modified and be made mutually complementary to optimise transmission. The compressor station employees are trained to respond to plant failures and are equipped with an emergency response vehicle.

Compressor stations comply with all environmental laws and regulations with regard to air emissions and noise abatement and they will not pose any environmental hazard. The automatic control and safety management systems and all the equipment will comply with the most stringent of Polish and EU standards.

The compressor, metering and system control stations are equipped with a state-of-the-art automated transport system which supports the following modes of operation:
  • Remote, from the main control room;
  • Local, from the compressor station control room;
  • Local, directly from the industrial control system.

The database management system supports the monitoring of every process at compressor stations through the use of advanced plant diagnostics and forecasting. Compressor stations have been equipped with redundant signalling and alarm systems.

Technical Data of Compressor Stations:

Inlet pressure of gas flowing into compressor stations – 5.65 to 6.35 MPa
Exhaust pressure of gas flowing out of compressor stations – 8.40 MPa
Gas flow rate – ca 4 200 000 Nm³/h
Gas temperature – ca 12^oC
Nominal revolutions of the turbocompressor – 7, 700 rpm
Turbine efficiency in nominal point – 36%
Compressor efficiency in nominal point - >84%

The transmission capacity of the Polish section of the Yamal gas pipeline is expected to reach 32.9 billion cubic metres per year after the completion of compressor stations in Szamotuły, Zambrów and Ciechanów (according to GOST).

The construction of Phase 1, the compressor and metering station in Kondratki, was completed in December 1999. Three 25 MW turbocompressor units were installed. The general contractor was PHZ Bartimpex SA and ABB Zamech Gazpetro Sp. z o.o. was the building contractor.

All tests of the plant and control systems, as well as the start-up were successful. In December 1999, EuRoPol GAZ was granted permission to operate the three compressor and metering station units at Kondratki.

The facility at Kondratki took a record 17 months to construct.

Phase 2 of project, the addition of the fourth 25 MW turbocompressor unit and the related pipework, was completed in December 2000. Permission was granted for the operation of Phase 2 integrated into Phase 1. Currently, the compressor station consists of four 25 MW turbocompressor units. Another two units are planned to serve the total of two gas pipelines in the transit system.

In October 2000, ABB Zamech Gazpetro Sp. z o.o. completed the construction of the compressor station with a system control and metering facility in Włocławek. The station has three 25 MW turbocompressor units. The construction of the fourth unit is anticipated to serve the total of two gas pipelines in the transit system.

The external infrastructure of the compressor and metering station at Kondratki was constructed by the Przedsiębiorstwo Państwowe – Zakład Wykonawstwa Sieci Elektrycznych (a state-owned electric grid contractor) based in Białystok, Poland; the infrastructure for the compressor and the reduction and metering station at Włocławek was developed by Zakład Remontowy Urządzeń Gazowniczych (gas plant maintenance company) based in Toruń, Poland.

The main plant, including compressors and turbines, was supplied by Alstom Power Zamech, in partnership with Dresser-Rand and Alstom Power Stal.
Other contractors were: Energomontaż Północ S.A., Gazobudowa Zabrze, ABB Instal Ltd., NIPA Białystok, ABB Centrum, Rembud Włocławek, Elektromont 1 Konin, Famet Kędzierzyn-Koźle.

In December 2003, the Supervisory Board of EuRoPol Gaz passed a resolution to give a go-ahead for the construction of compressor stations in Ciechanów and Szamotuły.

The implementation of the contract signed with PHZ Bartimpex and ABB Zamech Gazpetro commenced on December 31, 2003. The completion of construction works and the commissioning are scheduled for mid-2005. The construction project is expected to take 18 months.

The cornerstone laying ceremony in Ciechanów took place on March 10, 2004 in the presence of representatives of EuRoPol Gaz shareholders, the general contractor and contractors.

The compressor stations have been designed by Biuro Projektowe Gazoprojekt S.A., Wrocław, Poland. 

The Polish Register of Ships, an internationally recognised certification institution, is the project engineer and certification authority.

All matters regarding state-of-the-art solutions beyond existing industry practice were consulted with specialist companies such as ILF Beratende Ingenieure GmbH, Germany, and Giprogazcentr, Russia.

The contractors for the external infrastructure (energy grid, roads, drainage) at Ciechanów were local companies such as the Płock Energy Distribution Company, Energy District Ciechanów, Przedsiębiorstwo Robót Inżynieryjno-Drogowych (road engineering and construction) in Ciechanów, Przedsiębiorstwo Robót Wodno-Inżynieryjnych (water structure engineering) in Ciechanów. The contractor for the compressor station in Szamotuły was Gazomontaż SA, Wołomin, Poland.

The newly constructed compressor stations will be equipped with plant from the same vendors (however, their shareholders have changed). Demag Delaval Industrial Turbomachinery Sp. z o.o. Elbląg, Poland, will supply Siemens turbosets. Compressors will be supplied by Dresser-Rand. Compressor components will be assembled in Demag Delaval Industrial Turbomachinery Sp. z o.o. in Elbląg.

Pipes and fixtures will be supplied by Beroha Polska; coolers and gas filters – by Famet Polska; ball valves – by a Czech company, MSA a.s.; control valves – by an international corporation CCI; reverse valves – by  Noreva; power supply components – by  ABB. Much of the other plant will be supplied by Polish companies.

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