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Sakhalin Projects

Sakhalin I Chayvo Onshore Processing Facility

is an oil & gas processing facility which processes 34,000 metric tons (250,000 barrels) per day crude oil and 22.4 million m3 (800 million ft3) per day gas produced from the Sakhalin I fields.

Sakhalin I DeKastri Oil Export Terminal

is one of the biggest oil terminals in the Far East that serves as a hub for crude oil deliveries to Asian markets.

Sakhalin II (OPF) Onshore Processing Facility

located in the Nogliki district, 7 km inland in the north-east of Sakhalin Island, is the first combined oil & gas processing facility built in Russia and the largest of its kind globally.

Sakhalin I Chayvo Onshore Processing Facility

Sakhalin I Onshore Processing Facility is an oil & gas processing facility which processes 34,000 metric tons (250,000 barrels) per day crude oil and 22.4 million m3 (800 million ft3) per day gas produced from the Sakhalin I fields (Chayvo, Odoptu and Arkutun-Dagi).

Located off the north-eastern shore of Sakhalin Island, the Sakhalin-I Project was developed within the framework of a product sharing agreement signed between a consortium of Russian, Indian, Japanese and U.S. companies and the Russian government. Signed in 1996, the agreement covered the Chayvo, Odoptu and Arkutun-Dagi fields where potential recoverable resources were 307 million tons of oil and 485 billion m³ of natural gas. The crude oil is stabilized for shipment to the international market (through De Kastri Oil Export Terminal built by ENKA) and gas is separated for re-injection to the field to maintain
reservoir pressure, or treated and supplied to the Russian domestic market.

In May 2005, ENKA was awarded the contract for the installation of the mechanical and piping systems for the Onshore Processing Facility by Fluor Daniel Eurasia Inc. the EPCM Contractor, on behalf of Exxon Neftegas Limited.

ENKA completed the works at Onshore Processing Facility by the end of December 2006, two months ahead of schedule with 800 personnel at peak and a total of 2.8 million person-hours without any lost time incident.

Project Description

Sakhalin I Chayvo Onshore Processing Facility Project

  • Engineering
  • Procurement
  • Transport and Logistics of Main Equipment & Materials
  • Construction

Project Features

Contract Type
Reimbursable with Fixed Day Rates
Scope of Work
Engineering, Procurement, Transport and Logistics of Main Equipment & Materials, Construction
Client
ENL (Exxon Nefte-Gas Ltd.)
Consultant
Fluor Daniel Eurasia Inc.
Contractor
ENKA Main Contractor
Key Quantities
Erection of Field Piping40,000 m
Installation of equipment including compressors, generators, heat exchangers, boilers and pumps64 ea
Erection of pre-fabricated modules (900-2,500 tons)40,000 tons
Erection of Steel4,100 tons
Project Duration
Start Date03.05.2005
Finish Date01.12.2006
Duration19 Months

Location

Chayvo, Sakhalin Island, Russian Federation
UNIQUE CHALLENGES

To construct the Onshore Processing Facility, a modular approach was used, which helped cut field man-hours significantly. In less than three years, 36 modules weighing between 800-4,200 tons with a total of 40,000 tons were fabricated in Busan, Korea and transported to site in two major sea-lifts conducted during ice free summer windows of years 2005 and 2006. The modules were transported by means of oceangoing barges, rolled off at the offloading jetty at Chayvo, transported to Onshore Processing Facility site on self-propelled modular transporters and put directly on pile caps prepared earlier.

ENKA not only performed the hook up of these prefabricated modules, but also a substantial amount of stick built site erection work during very harsh two winters, including required field modifications to prefabricated modules and erection of their loose delivered parts, erection of freestanding equipment, various stick built pipe racks and all interconnecting piping works. ENKA also provided plant commissioning and startup assistance to the client.

Sakhalin I Onshore Processing Facility is located at Chayvo which is 120 km north of Sakhalin II Onshore Processing Facility site and challenges in terms of logistics, climatic conditions and supplies were similar. Those challenges were addressed by ENKA in most efficient manner by means of proper planning and execution.

ENKA SCOPE OF SERVICES

ENKA scope comprised the erection and installation of various static and rotating process equipment including compressors, generators, heat exchangers, boilers and pumps; field erection of 40,000 tons of prefabricated modules weighing between 900 and 2,500 tons and field erection of 4,100 tons of steel as well as 40,000 m of field piping, including fitting, welding, pressure tests, painting and insulation. ENKA also performed all scaffolding and winterization works for all disciplines at the Onshore Processing Facility Site & Orlan Platform during the project and provided commissioning and start-up support to the client.

SIGNIFICANT FEATURES AND ACCOMPLISHMENT
  • Provided significant training opportunities and turned many local craft with little or no disciplined industrial construction work experience into productive workers
  • Raised awareness relating to health, safety, environment, security and quality amongst direct hired personnel and subcontractors
  • Accomplished Stick-Built Scope on time throughout a harsh winter to be ready for major 2006 Sealifts
  • Successful 2005 & 2006 Sealifts from Busan, Korea with on time hook-up’s at Site

Sakhalin I DeKastri Oil Export Terminal

De-Kastri Oil Terminal is an oil export terminal located 6 km away from the village of De-Kastri in Khabarovsk Krai, Russia. It is one of the biggest oil terminals in the Far East that serves as a hub for crude oil deliveries to Asian markets.

The terminal, which started operations in 2006, belongs to the Sakhalin-I consortium led by Exxon Neftegas Ltd., which also includes 20% stake held by Russian affiliates of Rosneft:Sakhalinmorneftegas-Shelf and RN-Astra. The overall capacity of the export terminal is approximately 88 million barrels per annum of oil. Tanker loading capacity is suitable for Aframax tankers up to 110,000 DWT. The five Aframax tankers servicing the terminal are purpose-designed double-hull ice class vessels. The area of the terminal covers nearly 256,000 m2.

In November 2009, during the International congress Oil Terminal 2009 held in Saint Petersburg, De-Kastri terminal won the “Terminal of the Year Award”. The Award for the Terminal of the Year with a capacity of shipment of more than 5 million tonnes per year is presented to an international terminal with best economic, ecological and social indicators once in every three years. De-Kastri terminal was nominated among a total of 34 candidates. Since 2006, nearly 300 oil tankers have transported more than 30 million tonnes of crude oil from the terminal without a single incident or shutdown. De-Kastri’s SBM loading is considered to be the largest in the industry.

Project Description

Sakhalin I DeKastri Oil Export Terminal

  • Engineering
  • Procurement
  • Construction

Project Features

Scope of Work
Engineering, Procurement, Construction
Client
Sakhalin 1 Consortium: Exxon Neftegas Ltd, Sodeco, ONGC of India, Sakhalinmor-Neftegas & Rosneft
Contractor
ENKA – TECHNOSTROY-EXPORT Joint Venture
Project Duration
Start Date18.11.2003
Finish Date30.07.2007
Duration45 Months

Location

De-Kastri, Mainland, Russian Federation
UNIQUE CHALLENGES

De-Kastri is located in the far north-eastern mainland of the Russian Federation opposite to Sakhalin Island in the Pacific Ocean in the Khabarovsk Region of the Russian Federation.

De-Kastri site teams achieved an outstanding performance during very harsh four winters including the mobilization phase, which leaded the final destination of entire Sakhalin 1 Project’s De-Kastri Terminal to a successful completion.

ENKA SCOPE OF SERVICES

The first contract signed with Exxon Neftegas Limited included the construction of an offsite camp and temporary site facilities, the clearance and grubbing of trees and shrubbery in an area of 256,000 sqm, as well as site preparation and earthworks amounting to 1 million cubic meters, surface water drainage, land drainage, fencing works for the entire De-Kastri Oil Export Terminal Area, in addition to slope protection, road construction, stone paving and steel structure erection works for the buildings within Terminal Area. At the request of the client, while these works were underway, the reconstruction of the site access road, the EPC delivery of a sewage treatment plant and the supply and delivery of 150,000 m3 of crushed stone from a crusher plant established by the contractor were also performed.

Following the first contract, other mechanical erection works, spool fabrication and piping works, additional fill and site clearance works have been awarded by the client for the same facility. All works under both contracts, to date, total more than 2 million person-hours without any Lost Time Incident (LTI). After putting into operation of the Oil Export Terminal, ENKA continued to provide operation support services to Exxon Neftegas Limited until July, 2007.

SIGNIFICANT FEATURES AND ACCOMPLISHMENT
  • Provided significant training opportunities and turned many local craft with little or no disciplined industrial construction work experience into productive workers
  • Raised awareness relating to health, safety, environment, security and quality amongst direct hired personnel and subcontractors
  • Accomplished Civil, Structural, Mechanical & Electrical Scopes on time throughout harsh & long winters
  • Terminal of the Year with a capacity of shipment of more than 5 million tonnes per year.

Sakhalin II Onshore Processing Facility (OPF)

The Sakhalin II Onshore Processing Facility, located in the Nogliki district, 7 km inland in the north-east of Sakhalin Island, is the first combined oil & gas processing facility built in Russia and the largest of its kind globally. It is the key element of the Sakhalin II integrated oil and gas field development project, producing oil and gas from two major offshore fields located on the northeastern shelf of Sakhalin Island in the Okhotsk Sea.

ENKA, in a joint venture with Bechtel was awarded the contract in May 2003 for construction of the Onshore Processing Facility by Sakhalin Energy Investment Company Ltd., a consortium of Gazprom, Royal Dutch Shell, Mitsui and Mitsubishi.

The Onshore Processing Facility is capable of processing approximately 1,800 million scf/d of gas (51 million m3 /day) and about 60,000 b/d of condensate/oil (9,500 m3 /day). The facility separates, treats and processes the gas, gas condensate and crude oil received from offshore Lunskoye and Piltun-Astokhskoye fields, pumps the oil and gas to the liquefied natural gas plant and oil export terminals located in the south of Sakhalin Island.  In addition to the oil & gas process systems, the Onshore Processing Facility comprises extensive utilities and infrastructure necessary to support the flawless operations of this facility and also of the offshore drilling platforms located 30 km from the Onshore Processing Facility.

The first phase of the project was completed in 2006 and the second phase, comprising the extension and modifications, was commissioned in 2008. The Onshore Processing Facility project overall was completed with 30 million person-hours without any lost time incident.

First combined O&G Processing in Russia – Largest of its kind in the world

Project Description

Sakhalin II Onshore Processing Facility (OPF)

  • Partial Engineering
  • Procurement
  • Transport and Logistics of Main Equipment & Materials
  • Construction

Project Features

Contract Type
Phase I – Lump Sum with Fixed Unit Rates, Phase II – Reimbursable with Fixed Day Rates
Scope of Work
Partial Engineering, Procurement, Transport and Logistics of Main Equipment & Materials, Construction
Client
Sakhalin Energy Investment Company Ltd. (Royal Dutch Shell, Mitsui and Mitsubishi)
Contractor
BECHTEL – ENKA – TECHNOSTROYEXPORT Joint Venture
Key Quantities
Earthworks1.75 Mio m³
Cast in Situ Piling100,000 lm
Concrete95,000 m³
Structural Steel9,000 tons
Heavy Haul Equipment5,000 tons
Cabling2.80 Mio m
Pipe Fabrication78 km
Piping6,000 tons
Mechanical Installation7,000 tons
Painting & Insulation160,000 m2
Buildings13,000 m2
Project Duration
Start Date01.06.2003
Finish Date01.07.2009
Duration74 Months

Location

Sakhalin Island, Russian Federation
UNIQUE CHALLENGES

The Onshore Processing Facility was located in a remote area previously little touched by human activity. Due to lack of local availability, all resources, personnel, construction equipment, materials and consumables needed to be imported from Russian mainland or abroad. The poor infrastructure of Sakhalin Island and particularly remote location of the Onshore Processing Facility site made transportation and logistics an extremely challenging task on its own, which was further exacerbated by extremely harsh climatic conditions and other geologic hazards. In wintertime, heavy snowstorms cover the whole site and access roads with snow up to 3 meters thickness, and temperatures reach -35 degrees Celsius accompanied by strong winds, sea frozen during 6 months. In springtime, thawed ground water sink roads, while in summertime, thunderstorms, hurricanes, flash floods and earthquakes may be experienced several times a year, severe weather and extreme climate conditions were one of major challenges faced during the execution of this project.

The construction of Onshore Processing Facility was literally a continuous battle with Mother Nature. In order to overcome these challenges, life support services, supplies, logistics and overall construction execution had to be planned very carefully in each and every detail. ENKA developed robust sourcing, transportation and logistics plans complete with proper risk analysis and mitigation measures and successfully implemented them throughout the project duration.

Lack of skilled and unskilled labor on the Island created another challenge that required ENKA to bring labor from distant and various regions of the Russian Federation as well as expatriate personnel from Turkey and Asia Pacific countries. Due to remote location and harsh climatic conditions, special rotational schemes were implemented for labor. ENKA successfully managed these circumstances not allowing any productivity losses due to absence of personnel at any discipline with a strong human resources management program. During the execution of the project, also many residents of Sakhalin Island with little or no construction work  experience have been turned into productive and skilled craftsmen with extensive training.

Environmental issues at this highly sensitive area were also addressed with utmost care and the wild life surrounding the project site was protected with no harm.

ENKA SCOPE OF SERVICES

The scope of work included the design and construction of buildings, multi-discipline fabrication, construction and erection works and provision of commissioning and start-up assistance for the whole facility; and also procurement of bulk materials; material management; transportation and logistics of all process equipment and materials sourced worldwide and free-issued by the client/owner.

ENKA mobilized to the project site, set up temporary site facilities including a fully self-contained arctic construction camp with all required infrastructure and facilities to provide life support services for 2,500 people and maintained these facilities with all associated supplies for more than six years without any interruption. As part of early works, a 110 km long road was constructed through forested mountains in order to access the worksite from the nearest railway station. When hit by a snowstorm, which used to occur 2-3 times each winter, the Onshore Processing Facility site practically lost transport connection with the outer world, until the snow was cleared to uncover the site and access roads by its own machinery.

The heavy equipment had to be transported via sea, however there was no port and sea draft would not let standard vessels to approach the shore next to Onshore Processing Facility site. Therefore, the heavy equipment was brought to site by ENKA by means of beach landing operations conducted during summer (ice free) windows of years 2004 and 2005. The equipment were transported via ocean-going barges to Lunskoye bay, offloaded to smaller shallow draft barges offshore, which were then tugged or pulled up during high tide to land at the wild beach. After beach landing, the equipment was further transported by means of self-propelled motor trailers via an 8 km long heavy haul road to the Onshore Processing Facility site.

SIGNIFICANT FEATURES AND ACCOMPLISHMENT
  • First combined oil and gas processing facility built in Russia
  • Largest of its kind in the world
  • 31 million work-hours in total. 10 million person-hours without a Lost Time Incident achieved during construction. 6 million person-hours without a Lost Time Incident achieved in operating plant
  • Two successful beach landing operations for the major process equipment

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