The main component of the Tengizchevroil’s Asset Development Project, the Second Generation Plant, one of the largest and most complex projects undertaken in the oil & gas industry, aimed to expand the crude oil production capacity of the Tengiz field by 12 mtpa and significantly increase the production of associated dry gas, propane, butane and saleable sulfur products.

Major new surface facilities included the crude stabilization, gas processing and sulfur recovery plants, together with all required utilities including a major power generation and power distribution facility.

ENKA and Bechtel successfully carried out the two main multi-discipline construction components for the Second Generation Plant Project under a single contract in Tengiz, including civil, structural, mechanical, piping fabrication and installation, electrical, instrumentation, insulation, painting and building works.

Second Generation Plant Project Crude Stabilization and Gas Processing Multi-discipline Package

The Crude Stabilization Unit included facilities for inlet separation, crude desalting, crude stabilization, gas compression, and condensate stabilization. The Gas Processing Unit included facilities for the management of high-pressure sour gas, upstream removal of condensed liquids, and the removal of saturated outlet vapor stream, plus a molecular sieve unit for the removal of water.

Second Generation Plant Project Power Generation and On-plot Utilities Multi-discipline Package

Major facilities in the power generation area included a gas turbine hall with two GE Frame 9E gas turbine generators, each with a nominal rating of 123 MW, including all associated electrical, control and instrumentation equipment, and two supplementary-fired Heat Recovery Steam Generators (HRSGs), each capable of generating a maximum of 450 tons per hour of steam at 370°C and a pressure of 72 bar, using gas turbine exhaust gas and full supplementary firing, an electric switchyard, a combined substation and control building, and associated pipe racks.

ENKA and Bechtel also undertook the site preparation and early civil work, and construction of site’s temporary facilities, under separate early work contracts, prior to the awarding of the main SGP construction contract.

Remote location and hostile climatic conditions with temperatures ranging from +40 Celsius in summer to below -40 Celsius in winter created unique challenges for the project’s multi-national workforce. ENKA utilized construction best practices, its vast winterization experience, and extensive planning to address the challenges. Aggressive local content targets, high personnel peaks (up to 7,000) due to challenging schedule objectives and back-to-back working regime that is dictated by law were managed through a substantial craft training program. The brownfield features of the area were carefully addressed by implementing a robust HSE program resulted with minimum disruption due to simultaneous operations.

Bechtel-ENKA JV, through its local entity “Senimdi Kurylys LLP”, successfully executed the two main multi-discipline construction components for the SGP under a single contract in Tengiz inclusive of civil, structural, mechanical, piping fabrication and installation, electrical, instrumentation, insulation, painting and building works.

The Sour Gas Injection Project was one of the two main components of Tengizchevroil’s Asset Development Project, a world-scale program to significantly expand the crude oil production capacity of the Tengiz field. The SGI Project utilized state-of-the-art gas injection technology to enhance oil recovery and maintain reservoir pressure by re-injecting previously produced sour gas back into the reservoir.

Major new facilities included a Sour Gas Injection Plant and eight Injection Wells with associated equipment and facilities.

The SGI Project was divided into two stages:

Stage 1: Inject sweet gas from the processing facilities into the reservoir to test the operation of the compressor and validate the predicted response of the reservoir.

Stage 2: Expand the installation, permitting injection of high pressure sour gas from Second Generation Plant.

ENKA, together with Bechtel installed the compression and associated piping systems capable of safely and reliably delivering sour gas, into the 7,000 m deep reservoir at 10,000 PSI.