Reliable passive fire protection for proper productivity and quality
The Sakhalin-I project is a consortium that produces oil and gas on Sakhalin Island as well as offshore from three fields, Chayvo, Odoptu and Arkutun-Dagi, in the Okhotsk Sea (located in the Russian Far East). A production-sharing agreement was concluded between the Sakhalin-I consortium, the Russian Federation and the Sakhalin municipal government. The consortium is managed and operated by Exxon Neftegas Ltd (ENL). In 2003, the first Sakhalin-I well was drilled. Six of the world’s ten record-breaking extended-reach drilling wells have been drilled at the fields belonging to the project. On 27 August 2012, ENL beat its previous record by completing the Z-44 Chayvo well. This ERD well reaches a total depth of 12,376 meters (40,604 ft.), making it the deepest well in the world. The project is estimated to cost a total of USD 12 billion, which makes it the largest direct investment from foreign sources in Russia.
Quick and productive
Sakhwest, one of the contractors for scaffolding, blasting and fireproofing on site, initially opted for PITT-CHAR® XP intumescent coating according to Exxon Neftegas’s project specifications. Their plural component sprayer was not able to provide good productivity or quality because of harsh on-site conditions. Sakhwest therefore looked for a reliable sprayer that would help reduce start-up times, boost productivity and provide more efficiency while spraying. Proper technical assistance and training were also essential. Graco proposed XM PFP (Passive Fire Protection) technology as a solution for material applications. Since Sakhwest was also seeking to reduce the costs of possible quality failures, the key benefits for the end user were a local support network and availability of spare parts. Russian-speaking support by Graco played a major role in the final decision.
The operators noted the ease of operation. The results therefore fully met the customer’s expectations. After proper unit adjustments and additional training, PITT-CHAR® XP material was heated up relatively quickly and the fan could be opened less than one hour after start-up (even in cold weather conditions). “Ultimately, XM PFP enabled us to achieve a better performance rate, while at the same time keeping the quality consistent with no additional issues”, states Vadim Dolgov, Chief Specialist at Sakhwest.
Development of the Sakhalin-I project
It is estimated that the fields will yield 2.3 billion barrels of oil and 17.1 trillion cubic feet of natural gas. Current oil production is calculated at 250,000 barrels per day. The wells extend more than five miles underwater from the Sea of Okhotsk to the Odoptu oil reservoir. Future project plans call for the further development of natural gas resources in Chayvo that are not associated with current oil production. These development plans will call for the drilling of additional gas wells and the expansion of existing onshore and offshore facilities. This project will result in expanded gas sales to domestic and export markets.