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Development of Tengiz Oil Field

Since 1993, ENKA and Bechtel have been awarded and carried out an extensive range of assignments in the western region of the Republic of Kazakhstan. As part of the Bechtel-ENKA Joint Venture, ENKA has executed several major projects including the Debottlenecking Project and the Program 12, Tank Farm and Train 5 projects. All these have helped to develop the existing production capability and to increase the capacity of the oil field. Prior to August 2008, ENKA and Bechtel also carried out the Second Generation Plant and Sour Gas Injection projects for the Tengizchevroil.


ENKA and Bechtel also carried out: upgrading, replacement, modification and turnaround within the existing plant and wellhead sites; the installation of new wellsite flowlines, mechanical and electrical hook-ups at wellheads and metering stations; multidisciplinary planning support and prefabrication activities throughout the pre-turnaround phase, and installation works during the turnaround. 

The Second Generation Plant (SGP) Project: 

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.

Project Description

Second Generation Plant (SGP)Project

  • Procurement
  • Construction

Project Features

Contract Type
Lump Sum and Unit Rates
Scope of Work
Procurement, Construction
Contractor
Senimdi Kurylys LLP – a General Contractor ( Bechtel-ENKA Joint Venture)
Client
Tengizchevroil (TCO) (a Joint Venture between Chevron, ExxonMobil, LukArco and KazMunayGas, the Kazakh state oil firm
Key Quantities
Concrete96,000 m³
Structural Steel31,000 tons
Piping Prefabrication and Erection12,000 tons
Mechanical Equipment1,300 ea
Cable Laying Works2,600,000 m
Instruments57,000 ea
Project Duration
Start Date01.12.2003
Finish Date01.11.2008
Duration63 Months

Location

Tengiz, Republic of Kazakhstan
UNIQUE CHALLENGES

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.

ENKA SCOPE OF SERVICES

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.

SIGNIFICANT FEATURES AND ACCOMPLISHMENT
  • Up to 18.2 million hours worked without a lost time incident
  • The Second Generation Plant is the largest single sour crude processing train in the world. It not only have increased production, but the expansion has also helped to increase environmental protection and maximize energy efficiency through the use of advanced technology
  • Achieved 70% Kazakh content
  • Provided significant training opportunities and turned many local craft with little or no disciplined industrial construction work experience into productive industry professionals
  • Invested for a spool fabrication facility (that is the biggest capacity shop not only in Kazakhstan but in the region with 900 tons/month capacity with state of the art automation equipment with integrated NDT cabins, heat treatment furnaces and blasting/ painting facilities. Spool fabrication was completed within 14 months. The fabrication facility is still in operation as a sustainable value to the Kazakh economy
  • A phased completion methodology was implemented with successful First Oil production as early as February 2007 creating significant economic value to the project Owner.

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.

The Sour Gas Injection (SGI) Project:

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.

Project Description

The Sour Gas Injection (SGI) Project

  • Procurement
  • Construction

Project Features

Contract Type
Lump Sum and Unit Rates
Scope of Work
Procurement, Construction
Contractor
Senimdi Kurylys LLP – a General Contractor ( Bechtel -ENKA Joint Venture)
Client
Tengizchevroil (TCO) (a Joint Venture between Chevron, ExxonMobil, LukArco and KazMunayGas, the Kazakh state oil firm
Key Quantities
Piling2,500 ea
Concrete24,000 m³
Structural Steel2,400 tons
Piping Prefabrication and Erection2,000 tons
Heavy Wall Welding3,400 dia-inch
Mechanical Equipment450 ea
Cable Laying Works500,000 m
Instruments3,600 ea
Project Duration
Start Date01.11.2003
Finish Date01.11.2006
Duration36 Months

Installed a compressor and associated piping systems capable of delivering sour gas (17% H2S) into the reservoir at 10,000 PSI.

UNIQUE CHALLENGES

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, challenging schedule objectives and back-to-back working regime that is required by law were managed through a substantial craft training program. High operation (10,000 psi / 690 bar) pressure requirement to boost the H2S gas into 7000m reservoir dictated heavy wall (42~62 mm) thicknesses for 10~14 inch diameter pipework. These spools were welded and installed with special high technology automatic welding equipment. The installation and pre-commissioning of the Injection Compressor required specialized expertise. ENKA’s specialized operations team had successfully implemented the pre-commissioning of the compressor in two stages as explained above.

ENKA SCOPE OF SERVICES

ENKA and Bechtel successfully undertook multidiscipline work under six separate contracts, in accordance with the client’s contracting strategy, inclusive of site preparation, piling, civil, structural, mechanical, electrical, instrumentation and building work. They also successfully carried out turnaround work to convert the sweet gas injecting plant into an operational plant working with sour gas.

SIGNIFICANT FEATURES AND ACCOMPLISHMENT
  • 3 million hours worked without a lost time incident
  • The SGI/SGP Projects increased the oil production from 13 million tonnes to over 25 million tonnes per annum
  • Installed a compressor and associated piping systems capable of delivering sour gas (17% H2S) into the reservoir at 10,000 PSI
  • Achieved 75% Kazakh content
  • Provided significant training opportunities and turned many local craft with little or no disciplined industrial construction work experience into productive industry professionals
  • Successfully executed heavy wall welding with special automatic welding technology
  • Utilized world class operations personnel provided by ENKA Power (ENKA Subsidiary) to install the Injection Compressor with all the accessories, sealants, etc. and to pre-commission the plant successfully in two stages as described above.

Train 5 Project

The Train 5 project entailed the construction of a process group with an annual capacity of 2,5 million tons. The project contributed to the increase in the crude oil production capacity to 12 million tons of sweet crude per year as forecast in Tengizchevroil’s 5-year business plan. The project involved the engineering, supply of equipment and materials, and construction of the processing unit for crude separation, desalting, condensate srtipping, H2S removal and NGL recovery. The auxiliary units, built in addition to the main processing units, were a 2×40 MW gas turbine generator station, a 110 KV switchyard power management system, a high-pressure boiler plant, a nitrogen unit and a 100 t/hour water treatment plant.

Project Description

Train 5 – KTL 2.3 Additions to Tengiz Oil Processing Facilities

  • Engineering
  • Procurement
  • Construction

Project Features

Scope of Work
Engineering, Procurement, Construction
Contractor
Bechtel-ENKA Joint Venture (50 %)
Client
Tengizchevroil Limited
Key Quantities
Earthwork40,000 m³
Concrete28,000 m³
Steel Works4,800 tons
Piping150,000 m
Cabling600,000 m
Equipment277 ea
Piling Driven9,000 ea
Project Duration
Start Date26.06.1997
Finish Date01.08.2000
Duration39 Months

Gallery

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