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Sakhalin Projects

Sakhalin I (OPF) Onshore Oil Processing Facility

Signed in 1996, the agreement covered the Chayvo, Odoptu and Arkutun-Dagi fields where potential recoverable resources were 307 million t of oil and 485 billion m³ of natural gas.

Sakhalin I DeKastri Oil Export Terminal

ENKA executed the Civil, Mechanical and Completion Works for Project EPC-2 De Kastri Export Terminal

Sakhalin II (OPF) Onshore Processing Facility

The Sakhalin-II Project was developed within the framework of a product sharing agreement signed between a consortium of Japanese and U.S. companies and the Russian Government.

Sakhalin I (OPF) Onshore Oil Processing Facility

The Sakhalin-1 Project, operated by Exxon Neftegas Limited, is one of the largest single international direct investments in Russia and an excellent example of how advanced technologies are being applied to meet the challenges of the world’s growing energy demand. Over its years of production operations, the multi-billion dollar project has exhibited exemplary operational, environmental, and safety performance, and has provided significant benefits to Russia and its people.

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. Having taken effect in 1996, the agreement covers the Chayvo, Odoptu and Arkutun-Dagi fields where potential recoverable resources are 307 million tonnes of oil and 485 billion cubic meters of natural gas.

Oil & gas produced from the Sakhalin-1 fields is transported to the Chayvo Onshore Processing Facility (OPF), which stabilizes oil for shipment to the international market and gas for supply to the Russian domestic market or re-injection to the field to maintain reservoir pressure.

The OPF’s capacity is approximately 34,000 metric tons (250,000 barrels) of oil and 22.4 million cubic meters (800 million cubic feet) of gas per day.

Project Description

ENL Sakhalin I – EPC 2, Onshore Processing Facility (OPF), Chayvo

  • 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
Field Erected Piping 45,000 lm
Heavy Haul Eqpmt. & Module Inst. 100,000 m³
Structural Steel 3,000 tons
People on Cons. Site at Peak 750
Project Duration
Start Date 01.05.2005
Finish Date 01.10.2006
Duration 17 Months

Location

Chayvo, Sakhalin Island, Russian Federation
UNIQUE CHALLENGES

To construct the OPF, a modular approach was used, which helped cut field costs significantly and saved at least 18 months of overall construction time. In less than three years, the OPF team had fabricated 36 modules weighing a total of some 40,000 tons in Busan, Korea and completed two major sea-lifts and off-loads at Chayvo, hooked up the modules and completed plant commissioning and startup.

Meanwhile, OPF site teams achieved an outstanding performance of stick-built works during very harsh two winters, which leaded the Project to the success in association with afore mentioned sealifts.

ENKA SCOPE OF SERVICES

ENKA was the Mechanical & Piping Contractor to Chayvo OPF, where the scope consisted installation of 64 equipment including compressors, generators, heat exchangers, boilers and pumps; field erection of 40,000 tons of pre-fabricated modules weighing between 900 and 2,500 tons and field erection of 4,100 tons of steel as well as 40,000 meters of field piping, including fitting, welding, pressure tests, painting and insulation.

ENKA also performed all scaffolding and winterization works for all disciplines at the OPF Site & Orlan Platform during the Project.

OPF was 50% completed by the end of 2005 and full completion was successfully achieved by the end of 2006. A peak of 663 ENKA personnel including 58 administrative and 57 technical staff as well as 548 workers were employed in the Project by the end of 2005.

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, Russian Federation. 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 square meters.

The construction of the terminal started in 2003 and was completed by August 2007.

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

ENL Sakhalin I Oil Export Terminal Mechanical Works

  • 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 Date 01.11.2003
Finish Date 01.07.2007
Duration 45 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 cubic meters 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 man-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 Project is an integrated oil and gas field development project designed to enable year-round production from two major offshore fields, namely Piltun-Astokhskoye oil field and the Lunskoye natural gas field, located on the northeastern shelf of Sakhalin Island in the Okhotsk Sea. The project involved installation of two offshore production platforms (PA-B and LUN-A) along with the onshore infrastructure and facilities required for the sustained export of oil and gas. Crude oil and gas from the existing PA-A and the new PA-B platforms is delivered via separate pipelines to an onshore processing facility (OPF) located near the Lunskoye landfall. Gas and condensate from the new LUN-A platform is also delivered to the OPF via two 30-inch multi-phase pipelines. Gas from the OPF is then transported via a single onshore pipeline to a new LNG plant located at Prigorodnoye on the south coast of the island while crude oil and stabilized condensate is commingled and pumped together via a single onshore pipeline from the OPF to a new oil export terminal at Prigorodnoye.

The Onshore Processing Facility (OPF), located in the north-east of Sakhalin Island, 7 kilometers (4.3 mi) inland in Nogliki district, is the key element of the Sakhalin II development scheme. Major components of the OPF included facilities for three-phase inlet separation, condensate stabilization (two trains), gas dehydration, and dewpoint control along with two gas export compressors and two crude oil booster pumps. The OPF occupies a territory of over 62,000 m² and at full capacity 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 OPF is designed to be an entirely self-sufficient stand-alone facility. Utility systems installed at the OPF include flares, drainage, instrument/utility air, sewage treatment, potable and utility water, fuel gas and diesel, HVAC, chemical injection, fire water, and waste heat recovery systems. The facility also includes a 100 megawatt gas turbine driven power plant to generate power for the OPF itself and for the LUN-A platform.

The facility also includes storage tanks and associated handling equipment for condensate and crude oil, off-spec condensate, fresh water, potable water, fire water, diesel fuel, rich monoethylene glycol (MEG), lean MEG, and oil field chemicals, including demulsifiers, corrosion inhibitor, and neutralizer. Storage tanks at the OPF site are insulated and have rigid roofs capable of withstanding the snow and ice loading conditions of the area. Where required, tanks are equipped with heating coils for liquid viscosity and freeze control.

The OPF serves as the control and support center for all Northern Area production operations on Sakhalin Island. Buildings and support facilities at the site include an administration/ quarters building, guard house, warehouse/ maintenance building/fire station, central control building, utility building, power generation building, main substation, Train 1 and Train 2 substations, compressor building, rich/lean MEG pump house, crude oil booster pump house, open drain system pump house, sewage treatment building, chemical/paint store, and water-well buildings. All buildings are built to withstand the severe seismic loading conditions and harsh climate conditions at the site.

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

Project Description

Sakhalin II Project, Onshore Processing Facility (OPF) – Phase 1 & Phase 2 Nogliki

  • 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
Earthworks 1.75 Mio m³
Cast in Situ Piling 100,000 lm
Concrete 95,000 m³
Structural Steel 9,000 tons
Heavy Haul Equipment 5,000 tons
Cabling 2.80 Mio m
Pipe Fabrication 78 km
Piping 6,000 tons
Mechanical Installation 7,000 tons
Painting & Insulation 160,000 m2
Buildings 13,000 m2
Man-hour 30 Mio
Project Duration
Start Date 01.05.2003
Finish Date 01.07.2009
Duration 75 Months

Location

Sakhalin Island, Russian Federation
UNIQUE CHALLENGES

The OPF was located in remote area previously little touched by human activity. Sakhalin Island’s poor infrastructure made all personnel and material transportation to the site a challenging task on its own. Further, transportation was also restricted by harsh seasonal conditions frequently. ENKA mobilized to the Project Site, set up temporary site facilities including a 2,200 people camp and maintained these facilities with constant supply of fuel, water, food, supplies, and raw materials for more than six years without any interruption or problems.

Shortage of skilled and unskilled labor on the Island created a challenge and required ENKA to bring labor from distant and various regions of Russian Federation as well as expatriate personnel from Turkey and Asia Pacific countries. Due to remote location and harsh working conditions, special labor laws and 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, many local craft with little or no industrial construction work experience have been turned into productive and skilled craftsmen with extensive training.

Transportation of goods and materials to the site was limited not only by the seasonal conditions such as frozen seas, flash floods, or thawed ground water causing roads to sink but also the congestion at the Korsakov Port due to simultaneous execution of many projects for the Sakhalin II development. ENKA developed a transportation and logistics plan complete with proper risk analysis and mitigation measures and successfully implemented it throughout the project duration.

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

ENKA SCOPE OF SERVICES

ENKA, in a joint venture with Bechtel USA and Technostroyexport, a Russian company, was awarded the contract for construction of the OPF. ENKA’s scope of work included the design and construction of buildings, site facilities and access roads; installation of process equipment and piping; all main civil, mechanical, electrical, and instrumentation construction; testing and pre-commissioning of all constructed facilities; and provision of assistance with commissioning. Additional activities included procurement of bulk materials; materials management; transportation and logistics of all process equipment and materials free issued by the Owner.

The main work items completed during the first phase of the project were 1.75 million cubic meters of excavation, fill and road construction; 90 km of piles with diameters varying between 600-800 mm; 80,000 cubic meter of concrete, 28 km of underground pipe laying; 7,500 t of steel structure production and installation; 1.85 million m of cable laying; 78 km of piping fabrication, erection, insulation, and testing; and finally 6,000 t of various equipment erection, testing and commissioning of all these systems.

In October 2006, ENKA received a contract for the extension and modification of the facility which is completed by the end of year 2008.

Heavy Lift Cargoes and Beach-Landing Operations

ENKA has also undertaken the transportation and logistical activities for more than 28,200 t of free-issue material and equipment to the OPF jobsite in 1,932 shipments. Transportation of 4,600 t of heavy lift and oversized cargo, the heaviest piece weighing 325 t, has also been performed via beach landings at Lunskoye Bay, while contending with extreme climatic and environmental difficulties.

After collecting Heavy Lift Oversize (HLO) items from different vendor locations worldwide, these were delivered to cargo marshalling ports in South Korea and Japan and then loaded to ocean-going flat-top barges for delivery to Lunskoye Beach, via Korsakov for customs clearance.

A temporary landing facility was also set up twice on Lunskoye beach, in 2004 and 2005 for beach- landing operations. For heavy haul of HLO cargo from Lunskoye Beach to a temporary lay-down area, and then to the OPF site, self-propelled modular transporters and Nicolas trailers were employed. Environmental concerns and requirements were fully taken into account while these operations were underway.

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

Gallery

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