OILSANDS & OFFSHORE FABRICATION
Leveraging our extensive oil sands experience, Kiewit is at the forefront of providing solutions to mitigate the carbon footprint of oil sands operations. By utilizing and deploying technologies such as carbon capture, utilization and storage technologies — and integrating renewable energy sources — we offer comprehensive strategies that pave the way for a more sustainable future in oil sands.
Kiewit has executed nearly $7 billion in Canadian oil sands-related work over the last 10 years. Working at both steam-assisted gravity drainage and bitumen mining operations, our teams have completed general construction and module fabrication for froth treatment plants, fine tailings treatment plants, pipeline and process facilities, earthworks and infrastructure projects.
For more information on Kiewit’s fabrication capabilities across North America, click here.
A DECADE OF OIL SANDS AT THE KEARL MINE
KEARL OIL SANDS PROJECT | Fort McMurray, Alberta
The Kearl mine is one of Canada’s largest oil sands deposits with a gross production rate capacity of 220,000 barrels per day. The mining area contains approximately 4.6 billion barrels of bitumen resources which are expected to be recovered over a 40-year span. The production facility uses froth treatment technology to produce a blended bitumen that is transported to the Edmonton area via pipeline. Located over 40 miles from Fort McMurray, Alberta, the Kearl site contains a fly-in camp that houses rotational personnel and reduces commute time.
Kiewit began working at Kearl in 2006, undertaking site development and earthworks for the initial development phase. Over the next 13 years, Kiewit was contracted to execute various projects, including:
- Initial development froth treatment unit
- Expansion earthworks and froth treatment unit
- River water intake facility
- Deoxygenation facility
- Fine tailings facility
- Fine tailings thickener facility
- Tailings treatment mix box
- Supplemental crusher and hydrotransport interconnect
To optimize facility operations, reduce costs and minimize schedule, Kiewit participated in multiple front-end execution planning efforts with the owner and engineer prior to construction. Deliverables included risk-mitigation analysis, modularization studies, constructability reviews, preliminary scheduling, manpower curves and estimating.
Kiewit fabricated 645 modules at our yard in Edmonton, Alberta, including piperacks, valve skids, buildings, HVAC platforms and staircases. The team also dismantled, split and transported over 125 modules, fabricated in South Korea and shipped to U.S. ports to meet load permit requirements and clearances along the route. Turnouts, pull-offs, overnight parking, traffic structures and overhead utilities along Highway 12 through Idaho and Montana were modified to facilitate the transportation of modules to the Kearl site.
CHRISTINA LAKE OIL SANDS PROJECT
Kiewit completed two phases of the client’s staged plan for their Christina Lake oil sands development south of Fort McMurray, Alberta. Phase 1 included the construction of a 3,000-barrel-per-day, steam-assisted gravity drainage pilot facility, while Phase 2 increased capacity by 22,000 barrels per day. The two phases achieved a total design capacity of 25,000 barrels per day in just 10 months and were executed as Kiewit-led engineering, procurement and construction joint venture projects. By self-performing critical path elements, including the fabrication and setting of 118 modules, Kiewit was able to keep the project on time and on budget.
2.5 million manhours without a lost-time injury
SUNRISE ENERGY PROJECT
Fort McMurray, Alberta
The Sunrise field is estimated to hold 3.7 billion barrels of bitumen including 0.36 billion barrels of proved, 2.48 billion barrels of probable and 0.86 billion barrels of possible reserves. Kiewit supported the front-end engineering design of Husky Energy’s 120,000-barrel-per-day steam-assisted gravity drainage plant that produces oil from the Sunrise field. Kiewit co-located with the designer to provide constructability reviews, estimates, construction execution plans, a labor plan and camp accommodation recommendations.
Performed 150,000+ manhours with zero recordables
ATHABASCA OIL SANDS SCOTFORD UPGRADER EXPANSION
Fort Saskatchewan, Alberta
Ganotec Inc., a Kiewit Corporation subsidiary, fabricated modules and completed all scopes of work for the construction of the sole-sourced hydrogen manufacturing unit (HMU) for the Athabasca Oil Sands Project Scotford Upgrader Expansion. The Scotford Upgrader refines bitumen mined at the Shell Albian Sands mines near Fort McMurray and transported via pipeline northeast of Edmonton. The 100,000-barrel-per-day expansion, including the HMU, increased upgrading capacity at the Scotford Upgrader to 255,000 barrels per day of synthetic crude oil. Ganotec West was recognized for dedication and adherence to a strict and robust quality program for the HMU.