About Firebag Site

Suncor’s strategy was to improve the process of SAGD (steam-assisted gravity drainage) technology. Through upfront planning, design consideration and the application of that design, this owner and its contractor achieved great success by utilizing repeatable piperack, process module and building designs.

Creating Solutions

Waiward’s strategy was to assist Suncor and Jacobs by collaborating early on in the project to arrive at efficient connections, common material sizes and an overall design whereby multiple elements could be duplicated going forward. 3D models were eventually created to aid in this process. Throughout the project, the fabrication team implemented continuous improvement strategies to reduce waste and inefficiencies in the shop.

Exceptional Performance

Once at the point where the design was repeatable, obvious efficiencies were achieved, from engineering and detailing to delivery.

Waiward was able to reduce costs and schedule duration. Increased productivity resulted from the use of common materials, repeated fitting and welded requirements. In fact, Waiward reduced the fabrication schedule by approximately 25%, while the drafting and engineering savings totaled approximately 10% per module.

Unlike many other companies that must subcontract portions of the work, Waiward is a one-stop-shop for connection design, detailing, fabrication, coatings and delivery. Nothing needs to be sent out, allowing Waiward to provide a product that has been made safely, to the highest quality, and delivered when our clients require it.

About Firebag Site 3

Using their expertise, Waiward’s senior staff members partnered with Suncor and Jacobs to get involved in the early stages of Firebag 3 to identify possible changes that would optimize the project design and lower the total installed cost.

Creating Solutions

With open communication, engagement and upfront planning, Waiward, Suncor and Jacobs worked together, focusing on utilities and off-site piperacks. The teams studied the steel section depth and determined that by using deeper sections, they were able to minimize the number of supplementary reinforcements on the main beams and columns. If the design had been left as-is, the steel would have contained many stiffeners and doubler plates, leading to higher supply costs.

Exceptional Performance

Overall, the Firebag 3 project’s total cost was under budget by approximately 10%. A large part of this was due to Waiward’s partnership with Suncor and Jacobs on the main piperack, which helped reduce costs by roughly $1 million. In fact, Suncor estimated that the use of this same design throughout the plant would result in approximately $3 million in savings. By implementing upfront planning and ongoing collaboration, Waiward was able to reduce total installed cost, leading to both our success and the success of our client.