Barge Project Completed With Minimal On-Site Welding

Modular Reclaim Water Pump Barge for Kearl Oil

Expertise,
Industry

Allswater designed and integrated all systems for the Reclaim Water Pump Barge at Imperial Oil’s Kearl Oil Sands development. The barge is capable of processing between 4,000m3/hour and 13,500m3/hour of reclaim water from the tailings pond to the recycle water pond. The barge is capable of being floated to new locations over its 50-year service life.

Challenge

Northern Alberta is one of the most expensive construction locations on the planet. To deliver a cost-effective solution under these challenging conditions, it was essential to fabricate the barge’s main structures offsite, reducing on-site costs and complexities.

Solution

  • Prototype Development: Created a modular barge system prototype that balanced key design considerations:
    • Minimizing Buoyancy Volume and Steel Hull Weight: Ensuring the barge remained lightweight and efficient.
    • Maximizing Module Sizes for Transportation: Facilitating easier transport across Canada.
  • Optimized Build Strategy: Developed a strategy focused on:
    • Bolted Assembly: Utilizing bolted connections for major hull components to streamline fabrication and assembly processes.
  • Interdisciplinary Approach: Applied a highly inter-disciplinary methodology to navigate competing constraints and project requirements effectively.
  • Technical Coordination: Led the technical interfacing among various engineering disciplines, including:
    • Naval architecture
    • Civil engineering
    • Structural engineering
    • Process piping
    • HVAC
    • Electrical engineering
    • Mechanical engineering
  • Leadership in Technical Teams: Directed technical teams in developing and executing methods for:
    • Fabrication
    • Transportation
    • Sub-assembly
    • Final assembly processes
  • Project Management Support: Acted as an extension of the prime contractor’s project management team by providing:
    • Technical and commercial support throughout the entire project lifecycle
  • Document Management: Delivered reliable document management services for all engineering deliverables, coordinating inputs from:
    • Engineering firms
    • Shop drawing offices
    • Suppliers and sub-contractors

Results

  • Successful Installation: The barge was installed within the project’s transportation constraints with minimal on-site welding.
  • Early Commissioning: Commissioned well in advance of the client’s “first oil” date, demonstrating efficiency and proactive project management.
  • High Equipment Availability: Currently operating at high levels of equipment availability, ensuring reliable performance.
  • Market Expansion: The project solidified Allswater’s presence in the natural resources pump barge market segment. This success is evidenced by:
    • Second Order from Imperial Oil: Imperial Oil ordered a second sister-ship based on Allswater’s design to double the capacity of Kearl’s in-process water reclamation.
  • Ongoing Support: Allswater continues to support numerous pump barge projects in Alberta, providing expertise in:
    • Barge launches
    • Hull designs
    • Mooring analyses
    • Lifting and relocation engineering plans and studies