Produced Water Separation Capacity Expansion – Upper Zakum 750
Increasing Capacity from 100 KBPD to 150 KBPD Using Existing Equipment

The Challenge

In 2015, we supplied the separation internals and plate pack technology for a produced water separator on ADNOC’s Upper Zakum 750 development, originally designed for a capacity of 100 KBPD.

As production requirements increased, ADNOC needed to raise the separator capacity by 50%, from 100 KBPD to 150 KBPD. While the existing separator vessel remained suitable for service, the original plate pack did not have sufficient capacity to handle the increased flow.

Our Solution

Rather than requiring the installation of a new, larger separator vessel, our engineering team developed a custom extension to the existing plate pack.

The add-on was engineered to integrate with our original separation internals, increasing the effective plate pack capacity to meet the new 150 KBPD operating requirement while retaining the existing vessel.

The Result

The engineered retrofit delivered a 50% increase in produced water separation capacity without the need to replace the existing separator.

This provided ADNOC with a practical brownfield solution that maximised the value of existing equipment, reduced modification requirements and avoided the cost and complexity of installing a new vessel.

100 KBPD → 150 KBPD | 50% Capacity Increase | Existing Separator Retained