PROJECT NAME Karachaganak Main Works

LOCATION Kazakhstan

CLIENT Karachaganak Petroleum Operating BV

SCOPE Construction of a gas processing complex and export pipeline

DURATION 42 Months

DATE OF COMPLETION December 2003

The Karachaganak Main Works Contract

The Karachaganak Main Works Contract (KMWC) was a project for the development of the Karachaganak field, located in the far Western sector of Kazakhstan, a few kilometers from the Russian border. KMWC provides the export of up to 7 million tons per year of sweetened and stabilized condensate, in addition to 4.5 million tons previously produced and exported through the existing facilities.

The CCC/Saipem Consortium was awarded this challenging contract which encompassed the full construction of the Unit 2 & Gas Re-Injection, the Karachaganak Processing Complex (KPC), the gathering network connecting the wells and various units, 637 km of export pipelines and industrial buildings.

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Major quantities included over 100,000 m3 of concrete, 25,000 tons of piping, 20,000 tons of structural steel and 10,000 tons of equipment, 2,530 km of E&I cables and 637 km of pipeline. At peak, the project required more than 13,000 people and over 1,200 pieces of construction equipment.

This mega project is not only significant for its remote location, size and complexity but is marked by the severe continental climate with sharp seasonal changes, winter at plummeting temperatures of -40°C and summer at +40°C.