STATE OIL COMPANY OF AZERBAIJAN RESPUBLIC
(SOCAR)

OFFSHORE OIL and GAS PRODUCTION ORGANIZATION
(OOGPO)

Construction - Assembling Trust
"KHAZARDENIZNEFTGAZTIKINTI"
(KhDNGT)


Brief information about
"CASPMORNEFTEGAZSTROY" Trust

"CASPMORNEFTEGAZSTROY" Trust (CMNGS) is one of SOCAR subdivisions taking part in subconstract activities-development of offshore oil and gas deposits for driling, production, gathering and transportation of oil and gas. The main aim of the trust is to carry out works at deep water fields but the trust does not limit its activity by it and works at shallow water area and on shore.
There are 5 subdivisions of the trust which are specialized on the following kinds of work:
- 1-st subdivision (SSMF-1) carries out electric assembling works and fulfils system of electric power supply of electric power to users at all facilities of the offshore oil and gas branch. This subdivision built in 1972/74 for the first time in the world practice the overhead power line of 110 kV voltage on supports over sea of 50 km extension including distribution and transformer substations. Many number of subsea cables of 35 kV voltage were inclussively also run.

- 2-nd subdivision (SSMF-2) carries out mainly the construction of main onshore pipelines. This subdivision working at the construction of the main oil pipeline Baku-Supsa constructed and commissioned without remarks its part of the pipeline (~ 60 km).

- 3-rd subdivision (SSMF-3) carries out "turn-key" construction of offshore stationary platforms for drilling and production of gas at sea depth up to 130m. During from 1980 to 1991 years it has been constructed 7 platforms by the trust at the Guneshly field and 1 platform at the "Chirag" field which became the first acting platform of the Contract of the Century.

- 4-th subdivision (SSMF-4) carries out the construction of underwater pipelines (mainly-mains) with the help of the pipe laying barge (PLB "I.Guseynov" or "S.Vezirov") and oil and gas terminal construction, laying of pipeline by method of "free submergence" i.e. without usage of pipe laying ships. And also now the construction of small facilities both offshore and onshore. Just now this subdivision is commisioning the construction of the large oil terminal in Dubendi for reception and treatment of SOCAR oil of 60000 m3 volume.

- 5-th subvision (FMS) provides all abovementionaled subdivisions by motor-vehicle transport service and different handling equipment. Here mainly all vehicle flee is gathered including light duty autovehicles up to heavy duty trailers carrying loads up to 120t (Faun Verke) including huge ones like "Demag" type (CC-2000 and CC-4000) of carrying capacity up to 500t including.

Trust has a large production area including different production sites at different coastal places and among them at Caradag, Pirsagat, Cara-Chuhur, Dubendi etc. But the main trust base is at Zykh occupying the coastal developed site of more than 200000 m2 area.
This base was built for conveyer manufacturing of elements of offshore stationary platforms including jackets of 14000 t weight and also different top structures of the platforms and module.
There are next facilities at this base:
- Berth- pier 320x12=3840 m2 for mooring, loading and unloading ships of large tonnage.
- Roofed production shops of total area about 17000 m2 and among them welders training courses with the laboratory to carry out welds inspection.
- Office building and utilities.
- Oxygen station.
- Electric supply system.
- Railway branch.
- Open areas and among them occupied by gantry (railway) cranes of 50 t listing capacity.
All base perimeter is closed and under security. There are conditions for good rest and messing. The base is not far from the city, city transport including metro, all abovementioned features give possibility to use the Zykh base as one of the most reasonable and suitable sites in Azerbaijan to carry out the most different works, connected with the realization of different oil contracts at the Caspian sea.
The first experience of underwater pipeline construction was received by the Trust at the begining of underwater pipeline construction at the Caspian sea in 1963 and construction of four underwater pipelines between Jiloy island and the shore (20 km) of 200 mm (8") in diameter and 300 mm (12") in diameter by method of "free submergence". The construction was carried out by stringing from the shore step by step of ready being towed length (up to 1000 m) supplied by pontoons and their jointing. Successful commissioning of this facility opened the way for further development of underwater pipeline construction at the Caspian sea. Bare steel pipes, and if necessary iron addional loads were used to make the pipeline more heavy. Sea depth was not more than 40 m.
Since 1974 after the pipe laying large "Suleyman Vezirov" was put into exploitation and pipe concrete coating plant at the reinforced concrete products plant (Zykh) a new phase of underwater pipeline construction was begun namely:
- Usage of the pipe laying large (PLB).
- Usage of concrete coated pipes.
- Construction at sea depth up to 200 m.
Pipe laying large was used also while underwater pipelines at the Turkmenian section of the Caspian sea.
The large achievement of the underwater pipeline construction was construction of the unique object "Underwater crossing of the main gas pipeline USSR-Western Europe" via Kuybishev water storage basin. Unique state of the construction was that it was necessary during two summer navigation periods 1980/81 to lay 12 runs of 5 km each (total more than 60 km) of concrete coated pipes of 700 mm in diameter. Concrete coating of pipes was manufactured in Baku at the Zykh reinforced concrete products plant, these pipes were transported by sea ships from Baku via the Caspian sea up to Volga river to the point of construction. The object was successfully commissioned in time with high quality and without remarks from the Customer. Total length of laid pipelines is more than 4650 km and among them-near 700 km with the help of the PLB "S.Vezirov".
Near 40 km of underwater pipelines were laid at the Eastern section of the Caspian sea (Turkmenistan). Besides that near 40 km of underwater pipelines were laid at the Pacific ocean shelf in South-East Asia (Vietnam) near Vungtau town while development of the large oil field "White Tiger".
Begining from 1992 with the coming of European and American companies to Azerbaijan joint work on underwater pipeline construction was begun.
The first such object of joint works ("Pennzoil" company and "McDermott") was commissioning of the underwater main gas pipeline construction "Neft Dashlari - Bahar - AzGPZ" D 500/700 mm, length-near 120 km.
Then the Trust together with the Italian company "Saipem" took part in the construction of underwater pipeline from the offshore platform "Chirag-1" and among them:
~18 km, 600 mm in diameter (24") oil pipeline up to Sangachali terminal and
~50 km 400 mm (16") in diameter gas pipeline up to "Neft Dashlari".
None according to abovementioned objects the Trust had remarks, damages or accidents.
The trust pays large attention to questions of quality control at all phases of the technological process of carrying out of contract works in accordance with the approved system of control. This control is carried out by project authors (project institute) Customer, technical staff of the Trust at all phases and everywhere. Weld joints inspection is carried out by a special laboratory having all necessary means including x-ray, u-sonic and other inspection methods.
Special attention in the Trust is paid to questions of labour protection, safety and health protection. At present the standart including elements of ISO-14000 is developed at the Trust. The Trust has large number of high quality specialists with work experience more than 10-15 years. Total number of terminative workers is 1000-1100 persons and among them near 200 welders.
Great attention is paid at the Trust to questions of improvement of qualification of specialists. Different kinds of theoretical and practical training are carried out. Recently at the Trust with the help of Turkish Standart Institute TSI 30 engineers and specialists were trained according to Rules of ISO-9000 and ISO-14000. At present preparing of documentation for approving and receiving certificates ISO-9000 and ISO-14000 is carrying out. Together with the Finnish company ARO a large group of workers (near 100 persons) - welders and fitters - were trained in Finland. Also in Finland a group (20 persons) of engineers and technicians were trained at the courses to improve qualification and study ISO-9000 and ISO-14000 standards.
All these measures provide to keep degree of qualification of our specialists at a high level.
The Trust at present is in alliance with the Finnish company Aker Rauma Offshore (since 1997) and has some mutually carried out works and among them reconstruction of upper structures of Chirag-1 platform, semisubmersible drilling barges "Dede Gorgut", "Istiglal" and some other works.
Another our alliance works is together the company "AJ Crane" for mutual usage of large tonnage cranes of 200 - 500 t lifting capacity (CC-2000 and CC-4000) of "Demag" company.



"CASPMORNEFTEGAZSTROY" Trust assets.

Construction sites:

Construction - Assembling Trust "Caspmornefteqazstroy"(CMNGS) has a rather reasonable and suitable assembling-installing coastal base at Zykh for manufacturing and assembling (and among them of large block structures) metal structures of any designation.


Site # 1, total area 134 400 m2 includes:

1. Assembling - launching ways (slip) 140x25m - 2pcs, which permits to fulfil simultaneous assembling of two jackets of offshore platforms independantly from each other. Carrying capacity of these slips is 50 t/m2 ;
2. Roofed 2 span welding assembling shops - 3 pcs (on the general layout ## 1, 2 and 3) provided by over head travelling cranes with the lifting capacity - 50 t at each span, and of size (24 m x 72 m) x 2 =3456 m2 of each shop and total area of all three shops - 10368 m2;
3. Closed facilities with welding equipment at all necessary places;
4. Oxygen station for technical oxygen production of capacity - 280nm3/hour with filling - distribution unit to charge 60 oxygen cylinders / hour;
5. Electric power supply complex is to provide reliable work of all electric power users of the site including necessary quantity of welding posts, electric winches, pumps, compressors, lighting etc. All these works are supplied by the own electric substation 6/0.4 kW with two transformers of 1000 kWA eash, supplied by two feeding electric lines from the powerful regional 35/6 kW ("Azenergo") and situated at the distance of 350 m;
6. Practically there is possiblility for approach of large tonnage ships along all coastal line of 400 m extent;
7. Free of buildings net area for manufacturing of different installing assembling works near 95000 m2;
8. Reserve (abandoned) territory - 22400 m2;
9. Site # 1 along all coastal line is reinforced by steel piles protecting the coastal part of the site from disturbing actions of the sea;


Site # 2 total area - 72 950 m2 includes:

1. Berth - quay, pier for approaching , loading , unloading of large tonnage ships, of 320 m x 12 m =3840 m2 size;
2. Closed welding - assembling shop of 110m x30.5m = 3355m2 size with two overhead travelling cranes of lifting capacity - 50112.5t ;
3. Building of the welding laboratory (welding "school") with the overhead travellung crane of lifting capacity - 15t to provide fullscale training of welders and inspection laboratory;
Building 60 m x 16,5 m = 990 m2
4. Closed sling shop 82 m x 9.5 m = 780 m2 with necessary equipment for slings manufacturing;
5. Open welding - assembling sites of 42 m x 100 m = 4200m2 size - 3 pcs. With the gantry cranes of lifting capacity - 50t at each site and welding posts;
6. Machine shop with different metal machine tools and overhead travelling cranes of lifting capacity - 10t (2 cranes);
7. 3-storeyed administative building (central office of SMU-4) 32m x 12m size and total net area - 1152 m2;
8. 3-storeyed accomodation (shower rooms, cloak rooms etc) 32m x 12m size and total net area - 1152 m2;
9. Sawshop(for wooden materials) - 84m2 - 1pc;
10. Pump station (drain) - 12m2 - 1 pc;
11. Neighbouring to the site # 2 is a functioning railway branch;
12. The site is reliably supplied by electric power from the electric supplying complex with its own electric station 6/0,4 kW with two transformers 6/0,4 kW of 1000 kWA each and cable net laid in closed concrete cable routes.

As one can see both sites have all necessary things and provide full series of works for manufacturing of metal structures of any designation .
Among other works fulfiled by CMNGS Trust at this base after its foundation since 1980 up to 1991 there were "turn-key" constructed 8 (eight) deep water offshore platforms for sea depth - 100 ? 125 m.
It is nesessary to remark that small range from the city and main location always especially attractive feature for working personal who do not spend much time to go to the work and back to home.
Both sites including Zykh base have a closed perimeter and are under security.
Though all working personal at the Zykh base are provided by all necessary things (for study, messing, rest etc.) if necessary it is possible to make additional comfortable conditions for more number of workers.
All above mentioned and small charge of work place capacity of sites, absence of large quantity of work create real prerequisites to carry out works for manufacturing the most complex and large-sized structures.
It gives possibility to transfer the whole Zykh base of CMNGS Trust into the most reasonable and suitable sites in Azerbaijan for carrying out different works connected with realization of international oil contracts at the Caspian shelf.



Previous work experience in similar projects.


1993-1994
Contract name Gas utilization. Underwater gas pipeline construction,
L=65 km, diam.=20" and L=50 km, diam.=28" and
P=55 bar.
Country Azerbaijan
Contract party Sole contractor
Total contract sum 51.768.721 $
Duration 1 year and 6 months


1993-1994
Contract name Gas utilization. Construction of the Gas Compressor
Station, Q = 3.700.000 m3/day, P=55 bar.
Country Azerbaijan
Customer SOCAR
Contract party Sole contractor
Total contract sum 69.619.957 $
Duration 1 year and 6 months


1997-1997
Contract name Construction of the underwater oil pipeline Chirag-1 -
Sangachali. D = 24", L = 177,4 km, P=70 bar.
Country Azerbaijan
Customer AIOC
Contract party Partner of the joint venture (together with "Saipem")
Total contract sum 98.400.000 $
Accountable contract sum 29.520.000 $
Duration 4 months


1997-1998
Contract name Construction of the underwater gas pipeline Chirag-1 -
Neft Dashlari, D = 16", L = 48,2 km, P = 40 bar.
Country Azerbaijan
Customer AIOC
Contract party Partner of the joint venture (together with "Saipem")
Total contract sum 28.200.000 $
Accountable contract sum 8.460.000 $
Duration 1 month


1997-1998
Contract name Construction of the main oil pipeline Baku - Supsa
(Western variant of the export pipeline). D = 500 mm,
L = 480 km, P = 64 bar.
Country Azerbaijan
Customer AIOC
Contract party Subcontractor (of "Tekfen" conpany)
Total contract sum 61.538.462 $
Subcontract sum 7.948.718 $
Duration 10 months


1998-2000
Contract name Construction of the Central station of gathering, treatment and transportation of vendible oil in Dubendi, Q=30000 m3/day
Country Azerbaijan
Customer SOCAR
Contract party Sole contractor
Total contract sum 7.798.308 $
Duration 2 years and 8 months


1998-1999
Contract name Reconstruction of Booster Gas Compression Station,
Q=5.800.000 m3/day, P=55 bar.
Country Azerbaijan
Customer SOCAR
Contract party Sole contractor
Total contract sum 10.056.185 $
Duration 6 months


1998-1999
Contract name Construction of the underwater gas pipeline, Q = 325 mm, L = 19,25 km from the Chilov island up to
Gas Gathering Station Zyrya (village of Zyrya), P = 50 bar.
Country Azerbaijan
Customer SOCAR
Contract party Sole contractor
Total contract sum 4.020.180 $
Duration 8 months Dlay informatsiyi soobshayem nami bilo postroyen 400 km uchastok truboprovoda diametrom 530 mm Baku -Supsa