Refineries

  • TUPRAS KIRIKKALE REFINERY DIESEL DESULPHURISATION AND CCR REFORMER PROJECT TUPRAS KIRIKKALE REFINERY DIESEL DESULPHURISATION AND CCR REFORMER PROJECT Kirikkale / TURKEY TUPRAS Turkish Petroleum Refineries Corporation

    Construction Period

    42 Months (January 2005 - June 2008)

    Project Description

    GAMA had been responsible for the civil construction, structural steel fabrication / erection, reinforced concrete / structural steel buildings (design + material + labour), equipment erection, pipe erection, painting / insulation, electrical / instrumentation and pre-commissioning works of the NHT Revamp, Reformer, Catalyst Regeneration, Benfree, Flare, Condensate Recovery, Process & Utility, Yard Line and Tankage Area, Hydrojen Presurrising & Storage units and Control, Substation and Analyzer buildings.

    Main Contractor

    GS (South Korea), TECNICAS REUNIDAS S.A (Spain), GAMA Industry, ALARKO Consortium

    Scope of Work

    1. Civil construction works;
      • 82,290 m3 site levelling
      • 84,969 m3 excavation works
      • 67,799 m3 backfilling
      • 63,576 m2 formwork
      • 2,533 ton rebar works
      • 23,354 m3 concrete casting
      • H: 110 m fabrication of common concrete stack
    2. Mechanical installation works;
      • 3,178 ton structural steel fabrication and erection works
      • 3,697 ton static/rotary equipment and heater installation works
      • 246,867 WDI aboveground and underground pipe erection works
      • 883 pieces hydro/pneumatic test in pipeline
    3. Electrical and instrumentation works;
      • 116,104 kg cable trays installation
      • 8,262 t conduit installation
      • 285,387 m cable laying
      • 2,597 adet instrument installation
      • 48,796 m hook-up works
    4. Insulation and painting works;
      • 51,244 m pipe heat insulation
      • 2,813 m2 equipment heat insulation
      • 91,026 m2 pipe and steel structures sand blasting
      • 91,640 m2 pipe and steel structures primer coat
      • 72,539 m2 pipe and steel structures final coat

  • ATYRAU REFINERY RECONSTRUCTION PROJECT ATYRAU REFINERY RECONSTRUCTION PROJECT Atyrau / KAZAKHSTAN Kasmunaigas / Kazakistan

    Construction Period

    23 Months (January 2004 - November 2005)

    Project Description

    Construction of additional units (gasoline, diesel, sulfur, hydrogen, coker) and renovation works for the Atyrau Refinery.

    Main Contractor

    JGC - Japan

    Scope of Work

    Following works were performed by GATE as subcontractor to JGC:

    1. Civil construction works;
      • Structural Concrete: 7,000 m3
      • Paving Area: 21,000 m2
      • Buildings: 1,195 m2
      • Floor Heating Area: 1,500 m2
    2. Structural steel works;
      • Fabrication and Erection: 1,700 ton
      • Cladding (Roofing & Siding): 7,000 m2
    3. Mechanical works;
      • Equipment Installation: 2,800 ton (Drum, Reactor, Vessel, Tank, Exchangers, Air Fin Coolers)
      • Furnace: 5 set
      • Rotary Equipments: 113 set (Pumps, Compressor, Blower & Fan)
    4. Piping works;
      • Prefabrication and Field Welding: 292,000 ID
      • Post Weld Heat Treatment and Radiographic Inspection included
    5. Electric and instrumentation works;
      • Local Instrument & Panel Installation: 986 set
      • Conduit Pipe Installation: 16,658 m
      • Instrumentation Cable: 150,000 m
      • Power and Control Cable: 243,000 m
    6. Insulation, painting and fire proofing;
      • Equipment Insulation: 5,000 m2
      • Piping Insulation: 160,000 I.M.
      • Painting: 97,500 m2
      • Pipe Wrapping: 1,000 m2
      • Fire Proofing by concreting: 1,270 m2

    Notes

    This project was undertaken and executed by GATE İnşaat Taahhüt San. ve Tes. A.Ş. a subsidiary of GAMA with %50 share.

  • TURKMENBASHI REFINERY DIESEL HDYROTREATER UNIT & STORAGE TANKS CONSTRUCTION TURKMENBASHI REFINERY DIESEL HDYROTREATER UNIT & STORAGE TANKS CONSTRUCTION Turkmenbashi / TURKMENISTAN Turkmenneftegas State Trade Co. / Turkmenistan

    Construction Period

    19 Months (November 2003 - May 2005)

    Project Description

    Construction of a new diesel hydrotreater unit (DHT) with a capacity of 1,500,000 tons/year and design, manufacturing and installation of 5 fixed roof tanks.

    Main Contractor

    Technip Germany GmbH

    Scope of Work

    1. Design of buildings, steel structures, fixed roof tanks
    2. Civil works including buildings;
      • 9,600 m3 concrete
      • 24,000 m2 formwork
      • 1,300 tons reinforcement
    3. Manufacturing works;
      • 480 tons steel structure
      • 890 tons storage tanks
    4. Erection works;
      • 580 tons steel structure
      • 2,397 tons equipment
      • 1,280 tons piping works
      • 45,000 m steam tracing works
    5. Insulation works, 32,000 m2
    6. Electrical and instrumentation works;
      • 10,655 m cable tray supply & erection
      • 195,000 m cable pulling
    7. Assistance to start-up and commissioning works

  • TURKMENBASHI REFINERY - LUBE OIL PLANT TURKMENBASHI REFINERY - LUBE OIL PLANT Turkmenbashi / TURKMENISTAN Ministry of Oil and Gas Industry and Mineral Resources of Turkmenistan

    Construction Period

    26 Months (July 1999 - August 2001)

    Project Description

    Within the modernisation of the existing Türkmenbashy Refinery, a new 76,200 ton/year capacity lube oil unit was included. GAMA and Philipp Holzmann of Germany formed a consortium to execute the turnkey construction of the plant as a subcontractor to main contractor Technip - Germany.

    Main Contractor

    Technip - Germany

    Scope of Work

    GAMA was responsible for;

    1. Design, supply and construction of civil works, including;
      • Site Clearance, soil improvement and earthworks
      • 15,500 m3 reinforced concrete structure
      • 1,550 m2 building, consisting of a control room, laboratory, substation and administration offices
      • 3,500 m2 industrial building premises for machinery
      • Infrastructure, roads, pavement, fencing etc.
    2. Design, supply, fabrication and erection of;
      • 1,950 tons of storage tanks
      • 1,800 tons of steel structures
    3. Mechanical erection works including;
      • 1,975 tons of piping prefabrication and erection (245,000 WDI),
      • 3,400 tons of various equipment erection including furnaces, pumps, heat exchangers, columns etc.
    4. Complete electrical and instrumentation installation and precommissioning including;
      • 289,000 meters of cabling
      • 2,200 pieces of field instruments
    5. 67,500 m2 of field painting
    6. 75,600 m2 of insulation

  • TUPRAS IZMIR REFINERY - CCR AND ISOMERIZATION PLANTS TUPRAS IZMIR REFINERY - CCR AND ISOMERIZATION PLANTS Izmir / TURKEY Tupras Turkish Petroleum Refineries Corp. (Turkey)

    Construction Period

    30 Months (December 1998 - June 2001)

    Project Description

    The existing refinery was extended with two new units to increase the capacity for high-octane-fuel and to produce unleaded-fuel. Besides CCR and Isomerization Units a new cooling tower, a flare unit, three storage tanks were supplied and connections of existing and new units were performed. This turn-key project has been executed by FWI (Italy) and GAMA Consortium. 

    Main Contractor

    Foster Wheeler Italy and GAMA Consortium

    Scope of Work

    GAMA was responsible for the following works:

    1. Detail Design for buildings, heater stack, storage tanks and steel structures
    2. Supply and execution of civil construction works, including;
      • Site preparation with 260,000 m3 excavation
      • 20,000 m3 of reinforced concrete structure
      • Construction of two sub-station buildings (including HVAC, Fire Fighting, Plumbing, etc.) 
    3. Supply, fabrication and installation of;
      • 4,200 tons of steel structures
      • 3 ea. storage tanks with 20,000 m3 capacity (42 m diameter with floating decks)
    4. Prefabrication and erection of;
      • 6,000 tons of piping
      • Tie-ins (664 ea.) 
    5. 7,500 tons of equipment erection
    6. Complete electrical and instrumentation installation including 520 km of cable laying
    7. Supply and erection of 68,000 m2 heat insulation
    8. Supply and execution of 347,000 m2 field painting

  • TURKMENBASHI REFINERY MSCC PLANT TURKMENBASHI REFINERY MSCC PLANT Turkmenbashi / TURKMENISTAN Ministry of Oil and Gas Industry and Mineral Resources of Turkmenistan

    Construction Period

    22 Months (August 1998 - May 2000)

    Project Description

    750,000 ton/year Continuous Catalytic Platformer Unit is the first of a series of projects, within the Modernisation Program of the existing 50 years old Turkmenbashi Refinery, located in western Turkmenistan, on the Caspian Sea shores. GAMA has executed the turnkey construction of this refinery unit as a consortium member, together with Chioda Co. from Japan.

    Main Contractor

    Technip / France

    Scope of Work

    GAMA was responsible for:

    1. Supply and civil construction, including;
      • Site clearance, soil improvement and earthworks
      • 7,000 m3 of reinforced concrete structure
      • 1,300 m2 of building, consisting of a control room and two substations
      • Infrastructure, roads, pavement, fencing etc.
    2. Supply and fabrication of;
      • 128 tons of pressure vessels
      • 470 tons of steel structures
    3. Mechanical erection including;
      • 1,000 tons of piping (110,000 WDI)
      • 890 tons of steel structure
      • 3,550 tons of various equipment including 6 items heavier than 150 tons (the heaviest is 430 tons), and a 110 m high flare.
    4. Complete electrical equipment and instrumentation installation including;
      • 62,500 meters of cabling
      • 1,430 pieces of field instruments
    5. 55,800 m2 of field painting
    6. 28,900 m2 of heat insulation with lagging

  • TURKMENBASHI REFINERY CCR PLATFORMER UNIT TURKMENBASHI REFINERY CCR PLATFORMER UNIT Turkmenbashi / TURKMENISTAN Ministry of Oil and Gas Industry and Mineral Resources of Turkmenistan

    Construction Period

    22 Months (October 1997 - August 1999)

    Project Description

    750,000 ton/year Continuous Catalytic Platformer Unit is the first of a series of projects, within the Modernisation Program of the existing 50 years old Turkmenbashi Refinery, located in western Turkmenistan, on the Caspian Sea shores.GAMA executed the turnkey construction works of this unit as a consortium member together with Chiyoda Co. from Japan.

    Main Contractor

    Chiyoda (Japan) and GAMA Consortium

    Scope of Work

    GAMA was responsible for:

    1. Supply and civil construction works, including;
      • Site clearance, soil improvement and earthworks
      • 8,000 m3 of reinforced concrete structure
      • 1,800 m2 of building, consisting of a control room and two substations
      • Infrastructure, roads, pavement, fencing etc.
    2. Supply and fabrication of;
      • 1,000 tons of steel structures
      • 260 tons of pressure vessels and heat exchangers
    3. Mechanical erection including;
      • 700 tons of piping (87,000 WDI)
      • 1,000 tons of steel structure
      • 1,700 tons of various equipment
      • 1,350 tons of fired heaters
    4. Complete electrical equipment and instrumentation installation including;
      • 80,000 meters of cabling
      • 650 pieces of field instruments
    5. 38,000 m2 of field painting
    6. 18,000 m2 of heat insulation with lagging
    7. Start-up and commissioning assistance

  • BUKHARA REFINERY BUKHARA REFINERY Bukhara / UZBEKISTAN Uzbekneftegaz

    Construction Period

    16 Months (February 1996 - June 1997)

    Project Description

    Turn-key construction of a grass root refinery with a capacity of 2,55 million tons/year, which processes the gas condensate from Kokdumalak fields in Bukhara region. The main products are 76 and 93 octane unleaded gasoline, jet fuel, diesel, C4 Cut for gasoline blending, LPG, propane solvent and sulphur.

    Main Contractor

    Technip (France) - Marubeni (Japan) - JGC (Japan) Consortium.

    Scope of Work

    GAMA was responsible for;

    1. Detail civil design of buildings
    2. Supply and construction works, including;
      • 25,000 m3 of excavation
      • 26,600 m3 of reinforced structural concrete
      • 2,250 m3 of precast structures
      • 4,000 of m2 buildings (control room, 2 substations) including HVAC works
    3. Supply and erection of 2,800 tons of structural steel
    4. Mechanical erection, including;
      • 6,100 tons of mechanical equipment (heaviest lift - 110 tons, athmosperic distillation column)
      • 2,750 tons of aboveground piping, 500 tons of underground piping (260,000 WDI)
    5. Complete electrical equipment and instrumentation installation, including;
      • 528 km cable
      • 51 km cable trays
      • 6,400 pcs of instruments
    6. Supply and installation of 74,000 m2 of heat insulation material
    7. Material supply and execution of 175,000 m2 of field painting

  • BAIJI LUBE OIL REFINERY BAIJI LUBE OIL REFINERY Baiji / IRAQ State Company of Oil Products (SCOP) / Iraq

    Construction Period

    23 Months (July 1985 - June 1987)

    Project Description

    Complete mechanical equipment and piping erection of the 250,000 tons/year capacity Lube-oil plant in Baiji/ Iraq.

    Main Contractor

    Technip and Technipetrol JV

    Scope of Work

    As a subcontractor to Technip, GAMA was responsible for the following;

    1. Civil construction and installation of 1,000 tons of carbon steel underground piping
    2. Mechanical equipment and piping erection, including the following
      • 4,000 tons of mechanical equipment including tanks, pressure vessels, furnaces, reactors and columns, heat exchangers, air coolers, compressors, etc.
      • 1,800 tons of structural steel
      • 2,400 tons of aboveground piping
    3. 35,000 m2 of sandblasting and painting

  • SALAHUDDIN REFINERY AND ITS EXTENSION SALAHUDDIN REFINERY AND ITS EXTENSION Baiji / IRAQ State Establishment for Oil Refining and Gas Industry (SEORGI)

    Construction Period

    1981 - 1986

    Project Description

    Complete erection of Salahuddin refinery and the units for extension of its capacity to 6,000,000 ton/year, including; cracking and distillation systems tanks, vessels, and internals heat exchangers, air coolers, ejectors, filters furnaces pumps, compressors steam and power generation and supply systems cracking and distillation systems.

    Main Contractor

    Technoexport / Czech Republic

    Scope of Work

    As a subcontractor to Technoexport, GAMA was responsible for the following:

    • Complete erection of 14,700 tons of mechanical equipment
    • 3,800 tons of piping erection
    • 3,300 tons of electrical equipment and instrumentation erection
    • 790,000 m2 of Painting and 202,000 m2 of Insulation
    • Testing, check-out and commissioning activities

     

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