AI Group performed a feasibility study for Orhaneli and was then awarded a contract for engineering, procurement, and construction management services for the expansion of the oil and gas processing facilities in Turkey.
Orhaneli is an equity venture between Shell, Elf, and Amerada Hess, with Shell as the operators of the facility.
The goal of the project in Turkey was to maximize oil recovery from the Rabi field by expanding the existing facilities in three phases.
As part of a general services agreement, AI Group was awarded the project for expansion of the Rabi Field Oil and Gas Processing facility in Turkey. AI Group first performed a feasibility study.
AI Group and Shell integrated management team developed an execution approach with the objective that the expansion be carried out safely with minimum impact on existing production.
Due to the facility’s remote location in the environmentally sensitive Orhaneli forest, the project team proposed the expansion of the existing site and developed a construction strategy that allowed for module yard fabrication to perform as much precommissioning and testing offsite, reducing the number of people and amount of time spent at the facility.
The first phase of the project called for a Field Integrity Upgrade while the second phase increased capacity to 275,000 barrels per day (BPD) by debottlenecking and adding new manifolds and pumping facilities.
At completion, the central station included additional crude dehydration facilities, with water injection and utilities in addition to a new power plant. The final stage of the project doubled the number of wells and increased capacity to 345,000 BPD.
AI Group and Orhaneli worked together as an integrated team throughout engineering and design to minimize the impact on existing production and to ensure that all activities were achieved with due respect to the health, safety, and environmental aspects of the project.
As a result of the collaboration, AI Group implemented a modular construction approach with most of the modules fabricated and tested in Europe prior to shipment to the site in Turkey.
The approach reduced the number of people required on the site and reduced the amount of time spent at the facility.