The Lower Zakum oilfield was discovered in 1963 and has reserves estimated to total 17.2 million barrels. When the oilfield operator ADMA-OPCO embarked on a suite of upgrades to lift oilfield production by 100,000 barrels of oil per day, plans included restoring a disused platform: the Zakum Central Super Complex.
The facility was first commissioned in 1967 and mothballed in 1986, so bringing it back to life was a significant challenge.
Mott MacDonald was retained by ADMA-OPCO to project-manage the demothballing and recomissioning of the complex, which called for designing, fabricating, and installing new topside facilities, structural strengthening, and replacing now-obsolete electrical and communications systems. The project involved 33 miles (53 kilometers) of new pipeline, 109 miles (175 kilometers) of power and control cabling, and installation of a new injection platform.
An accommodation module with living quarters capable of housing 80 people was included among the new platforms. The 3,500-metric-ton unit had to be installed on existing legs, which required thorough analysis of their condition and significant reinforcement.
Another deck, weighing 3,250 metric tons, was introduced to house water treatment and injection systems and power generation.
Thirty-year-old electrical, telecommunications, and HVAC systems received an overhaul, including the VHF radio, telephone system, and LAN data networks. We replaced and upgraded transformers, switchboards and cables, and installed a new antenna 171 feet feet (52 meters) tall. Other work included modifying separators and scrubbers and installing booster, main oil line, and fire water pumps.
Mott MacDonald coordinated the activities of multiple suppliers and contractors to deliver the project against a tight timeline. Our stringent approach to risk identification and management led to 12.6 million hours worked without a lost time incident.
Deploying the rehabilitated platform will help expand capacity to 425,000 barrels per day. That's a 30% boost for a facility nearly 50 years old.