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UE-1 Upgrader Expansion

World’s largest fluid coker and single-train hydrogen plant

Syncrude Canada

Ft. McMurray, Alberta, Canada


Consulting, Engineering, Construction



Project 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

Project 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 and 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
  • HSSE designated as a core value within PMT and client, a new culture to Alberta
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