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Conducted in the Tengiz oil field, northeast of the Caspian Sea, this work covered the multi-layer containment system of waste ponds subject to hydrocarbon contact. The site's climatic conditions were highly challenging for geosynthetic installation: long freezing periods dropping to minus 30 °C in winter and strong steppe winds in summer kept the welding operation window much narrower than in Turkish or African sites.
The system was designed so that the geotextile layer, serving protection and filtration functions, would work together with the underlying HDPE geomembrane liner. The geotextile undertook the task of extending liner life by protecting the geomembrane against puncturing effects originating from subgrade irregularities and top loads. The wedge welding method was foundational for geomembrane welds, but welding machine preheating parameters were re-calibrated at low temperatures and trial welds were performed before each shift.
Carried out under the coordination of main contractor Enka, the work required full compliance with oil enterprise site safety protocols, so all crew members underwent HSE training; hot work permits were renewed daily, and weld points were completed in the presence of a fire watch. Delivered in the 2003-2004 season, the system joined the Tengiz operation as one of the early references of geosynthetic application in the oil and gas sector.
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