Case studies

Kuwait flag Water injection project, Kuwait

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Client: Kuwait Oil Company

Location: Kuwait

Project value: US$430 million

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Many oil fields around the world use water injection techniques to boost production. But what sets this project for Kuwait Oil Company (KOC) apart is the sheer scale and the high levels of injection pressure deployed.

Petrofac was awarded a US$430 million contract in 2010 for the engineering, procurement and construction of effluent and central sea water injection facilities. The project involved the installation of a new central injection pumping facility, as well as modifications to three of the existing gathering centres and a seawater treatment plant.

The project was one of a kind in the world due to the high amount of injection pressure of effluent and sea water.

Krishan Malhotra, Project Director

The project started with four brownfield and greenfield sites. Existing facilities were modified to provide effluent and sea water to the central injection and pumping facility. From here, effluent and sea water was delivered at high pressure to the injection wells through high-density polyethylene (HDPE) lined pipelines. It was the first time anywhere in the world that such high levels of injection pressure had been exerted on HDPE-lined pipes. And this, combined with the corrosive properties of the effluent and sea water, presented some complex safety and integrity considerations.

The team maintained an excellent safety record throughout, achieving more than 21 million man-hours with just one lost time injury, and received two consecutive American Society of Safety Engineers’ gold awards for HSE excellence. This is even more impressive given that we worked with multiple construction contractors, most of who were new to working with Petrofac. It was crucial that everyone worked to a consistent standard of safety that was acceptable to Petrofac.

The project was commissioned in stages, dovetailing construction completion, and the facility was turned over to KOC for operations in August 2014.

The completed plant now enables both effluent and sea water to be injected, at high pressure, through the intricate network of HDPE-lined pipelines, into the wells of nearby oil fields – thereby enhancing their oil recovery capacity.