Mastering steam generation equipment technology for oil and gas exploitation

In recent years, the need to improve technological autonomy in the oil and gas industry has become increasingly urgent.

Drilling rigs at Bach Ho field. Illustration photo: Huy Hung/VNA

High-pressure steam generating station, an important device in handling flow blockages caused by wax (paraffin) in oil pipelines, has long been dependent on imported sources with high costs and long waiting times. Faced with this reality, the group of authors at the Vietnam - Russia Joint Venture Electromechanical Enterprise Vietsovpetro has researched, designed and successfully manufactured a mobile high-pressure steam generating station. The project not only brings economic and technical value but also affirms the technological mastery capacity of the domestic engineering team.

The product has been effectively applied in oil and gas exploitation and was awarded Third Prize at the Vietnam Science and Technology Innovation Award 2024.

Proactive domestic technology

According to Master Trinh Hoang Linh, head of the research project, in the process of exploiting crude oil, the phenomenon of wax deposition in the pipeline system is a difficult problem. When the temperature drops, the wax in the oil will crystallize and stick to the pipe wall, causing blockage, seriously affecting the exploitation output. To handle this, units often use the method of pumping hot water or high-pressure steam to melt this wax layer.

Master Trinh Hoang Linh said that previously, all high-pressure steam generating station equipment had to be imported from abroad, mainly from a few traditional partners. However, due to recent geopolitical fluctuations, the supply chain from foreign manufacturers has been disrupted, affecting the progress and cost of importing equipment. Many essential materials cannot be imported on time, while similar products from other countries are either not suitable for the conditions at offshore oil and gas fields, or are too expensive. This makes maintaining continuous production more difficult than ever.

Based on that urgent need, the research team at Vietsovpetro Electromechanical Enterprise boldly proposed a plan to localize all equipment, proactively designing and manufacturing a mobile high-pressure steam generating station from domestic resources. The project focused on three main goals: Optimizing the frame structure, reducing size and weight for easy movement; choosing modern materials and combustion equipment to reduce fuel consumption; replacing the entire old control system with a more advanced control system, suitable for operating conditions at offshore oil and gas rigs.

The project implementation process requires synchronous coordination between design, material selection, manufacturing and quality control. Most components and accessories in the steam generating station are localized with international quality standards. The research team also proactively integrated an automatic control system, allowing close monitoring of indicators such as flow, temperature, pressure and operational safety.

To date, the Electromechanical Enterprise has successfully completed and delivered a high-pressure steam generating station coded VM-PSG-80-1000-295, meeting all international standards for installation on offshore structures. At the same time, 8 other steam generating stations have been manufactured according to the plan for 2024 and 2025.

From economic efficiency to practical application

The successful manufacture of mobile high-pressure steam generating stations not only brings clear economic efficiency to the operating unit, but also opens up a new direction in proactively designing and manufacturing equipment to serve key industries, especially offshore oil and gas exploitation, a field with strict requirements on technique and safety.

According to the research team's calculations, if we continue to use imported equipment from abroad, the cost of purchasing a high-pressure steam generating station (not fully integrated with a modern control system) is about 2.82 billion VND. If we add an advanced burner and controller, the total cost could be up to nearly 3 billion VND. Meanwhile, the cost of producing a similar station domestically is only about 2.5 billion VND. Thus, with 9 stations planned for production in the 2024-2025 period, the localization solution will help save more than 3.8 billion VND compared to the import option.

Not only does it have economic value, but complete control of the equipment design and manufacturing process also brings many other benefits. The localized steam generating station helps the unit to be more proactive in the inspection, maintenance and repair stages, no longer depending on foreign supplies with many risks in terms of time and cost. In addition, the equipment is manufactured according to environmentally friendly criteria, using modern control and combustion systems to reduce fuel consumption, limit emissions and ensure safety when operating at sea. The product not only meets the unit's operating requirements, but also has the potential to expand its application to other domestic oil and gas exploitation enterprises. In addition to the oil and gas sector, the mobile high-pressure steam generating station can be adjusted to serve chemical, food, waste treatment plants or industrial facilities that require high-pressure steam cleaning systems.

According to Master Trinh Hoang Linh, the success of the project also clearly reflects the positive impact of an increasingly favorable policy environment. Master Trinh Hoang Linh believes that the Politburo's issuance of Resolution No. 57 dated December 22, 2024 on breakthroughs in science, technology, innovation and national digital transformation is also a strong driving force for the research team to continue pursuing and implementing technical initiatives associated with production practices in the coming time.

According to VNA

Source: https://doanhnghiepvn.vn/cong-nghe/lam-chu-cong-nghe-thiet-bi-sinh-hoi-phuc-vu-khai-thac-dau-khi/20250626082030918