UE-1 Upgrader Expansion Project

Client:
Syncrude Canada
Location:
Ft. McMurray, AB, Canada
Scope:
EPCm Alliance Services including key leadership of an integrated Project
Management Team (PMT)
Status:
Completed - 2006
UE-1 Upgrader
Expansion
Project
World’s Largest Fluid Coker and Single Train Hydrogen Plant
Details:
•Phase 3 of a planned four-phase effort known as the Syncrude 21 suite of projects at the
Oil Sands Upgrader Facility
•KBR, Fluor, and SNC-Lavalin worked together with other lower-tier contractors in an integrated team at the project management headquarters in Calgary. Each company provided
key management and discipline personnel to the team.
•Objectives of project were to increase production capacity by 25% to 365,000 BPD of Syncrude Sweet Blend (SSB), increase efficiency, and improve product quality while enhancing
environmental performance
•Key quantities to be installed for this mega project include: 70,000 cubic yards of concrete,
1.3 million feet of pipe, and 40,000 tons of steel
Safety Highlights:
•HSSE designated as a core value within PMT and client, a new culture to Alberta
Continued on following page
Ft. McMurray, AB, Canada
Client:
Syncrude Canada
Location:
Ft. McMurray, AB, Canada
Scope:
EPCm Alliance Services including key leadership of an integrated Project
Management Team (PMT)
Status:
Completed - 2006
Page 2
UE-1 Upgrader
Expansion
Project
World’s Largest Fluid Coker and Single Train Hydrogen Plant
Highlights:
•KBR established as contractor of choice for construction management, and for self perform
work (over 2 million hours)
•Achieved consistent success in remote and cold weather environment with logistical &
resource challenges
•Created and implemented productivity enhancement program for the field with state of the
art tools (utilized PDS for planning/material control)
•Implemented unique material purchasing/control process with bulk/mill run strategies and
satellite marshalling facility for materials/equipment
•Fully-integrated project team led by KBR Project Director
•All work coordinated with an extensive ongoing maintenance shutdown program to ensure
no interruption of plant operations
•Studies were conducted to reduce costs and prioritize completion of certain units for an
early return on investment
•Due to the high cost of maintaining the construction labor force at the site, strategy
included significant modularization to maximize offsite work hours (over 900 modules and 2
million module assembly hours)
•5+ million total home office work hours
•17+ million construction work hours
Ft. McMurray, AB, Canada