Designing and integrating two Reclaim Water Pump Barges for a major oil sands project in Alberta
Efficient water management is a critical part of oil sands operations, helping to recycle water for bitumen extraction while mitigating environmental impact. To support this process, Allswater played a key role in designing and integrating two Reclaim Water Pump Barges for a major oil sands project in Alberta. The barges were required to move large volumes of reclaimed water with exceptional reliability and uptime, all while minimizing on-site construction costs in one of the most expensive build environments in the world.
Challenge
Operating in Northern Alberta presents a unique set of challenges, particularly for large-scale infrastructure projects. On-site construction costs are among the highest in the world, making it critical to minimize labour-intensive assembly and welding. Additionally, the remote location and harsh environmental conditions required a barge design that could withstand long-term operational demands while being transportable in prefabricated sections.
Another significant challenge was the engineering complexity of integrating various systems. The barge needed to support a high-volume water reclamation system, requiring seamless coordination between multiple disciplines, including naval architecture, structural engineering, mechanical and piping systems, HVAC, and electrical engineering. Any misalignment in design could lead to costly delays or inefficiencies.
Solution
To address these challenges, Allswater engineered an innovative modular, pontoon-based barge system that balanced function, performance, and cost efficiency. The design was developed with three core priorities:
- Prefabrication & Transportability – The barge sections were built in Atlantic Canada, maximizing module sizes for easy transport. Major hull components were designed to be assembled using bolted connections instead of traditional on-site welding, reducing assembly time and costs.
- Engineering Integration & Technical Coordination – Allswater led the technical development and coordination of multiple engineering disciplines, ensuring a seamless design and fabrication process. The team provided detailed engineering plans, vendor print approvals, shop drawings, and risk assessments to eliminate assembly errors and ensure regulatory compliance.
- Optimized Reliability & Performance – The barge was designed for maximum uptime, with a focus on system reliability and ease of maintenance. Following the success of the first barge, subtle design improvements were made for the second unit to further enhance operational efficiency.
By implementing this strategy, Allswater was able to deliver a cost-effective, transportable, and highly reliable solution that met the stringent requirements of the project.
Results
The project was successfully completed with minimal on-site welding and streamlined installation, allowing the barge to be deployed ahead of schedule. The first barge proved so effective that a second contract was awarded for a sister-ship, doubling the project’s impact.
- Efficient Installation: The modular design enabled the barge to be assembled and installed quickly, reducing construction costs in Alberta’s high-cost environment.
- Early Commissioning: The first barge was commissioned well before the project’s “first oil” milestone, demonstrating the efficiency of the design and project execution.
- Reliable Performance: The barges continue to operate with high equipment availability, ensuring uninterrupted water reclamation and supporting sustainable resource management.
- Market Expansion: The success of this project helped establish Allswater as a leader in pump barge engineering, leading to ongoing work in barge launches, hull design, mooring analyses, and relocation engineering in Alberta’s oil sands industry.
By leveraging a highly coordinated, modular approach, Allswater successfully delivered a cost-effective, scalable, and long-lasting solution for water reclamation in Alberta’s oil sands industry.