Sea Water Cooling System For Jubail 2 December 2007

ROYAL COMMISSION FOR JUBAIL & YANBU

Content

RC Mission and Achievements

Project Management Tools

Sea Water Cooling in Jubail 1

Jubail 2 Sea Water Cooling

- Feasibility & Concept

- System Overview

- Project Status.

Strategic Master Planning of the development and the

future growth

Provide land and utilities for industrial development.

Promote industrial, residential and commercial

investment.

Develop , operate and maintain public facilities and

services.

Comprehensive Management of the two cities.

Royal Commission Mission

Produces 7% of the world’s petrochemicals.

Contributes 11.5% of the Kingdom’s non-oil GDP.

Creates 70% of the Kingdom’s non-oil exports.

Annual growth is sustained at 6%.

Jubail has attracted over 50% of the Kingdom’s total

foreign investment.

Achievements ( In Jubail )

Jubail is the Best City in attracting foreign investment,

award by Financial Times , 2005

1 : 4 1 : 15Industrial Capital Invest.

240

16

RC Capital Invest.

RC & Industrial Sector Capital

Investment ( SR Billion)

JUBAIL 2JUBAIL 1

193

47

Industrial Capital Invest.

RC Capital Invest.

STAGE 1 STAGE 2 STAGE 3 STAGE 4 STAGE 5 STAGE 6

2 W 2 W 24 W 16 W 4 W 104 W

CONCEPT PLAN COMTT DESIGN CONTRACTING APPROVALS EXCUTION

PROJECT SPONSOR PROJECT SPONSOR PROJECT SPONSOR PROCURMT- DEPT PROCURMT DEPT CONST/ENG

DDG

GATEKEEPER

BREIF SCOPE

ROUGH COST

WHY DO WE NEED

THE PROJECT

BREIF SCOPE

COST +- 25 %

BUDGET VERIFICATION

PROCESS CICLE

(STGs (3-6))

PROJECT NEED

SCHEMATIC DEWG

PROJECT TITLE

DISCUSS A/E

30% DESIGN

VE+ DEPTS REV

2 W

4 W

2 W

90% DESIGN 12 W

DEPTS REVIEW + 2 W

100 % DESIGN 2 W

TRANSLATION

RFP

ISSUE FOR BIDS+

RC EST

EVALUATION+RECOMMO

NDATION

2 W

8 W

3 W

DG APPROVAL 2 D

NEGT BIDDER 3 W

PLANNING PHASE PROCESS PHASE IMPL - PHASE

CHAIRMAN

MOF

BOARD

2 W

COM

2 W

PARALELL

2 W

4 W

1 - 3 W 1 - 3 W 16 - 48 W 12 - 24 W 2 - 12 W 52 - 208 W

TO BE PREPARED BY

REQUESTER THRU

AFORMAT

A FORM -

TO BE PREPARED BY

REQUESTER THRU

POWER POINT

PRESENTATION

FORM -B

REVISED

CFRREVISED

CFRREVISED

CFR CONST/ENG

CUSTUDY

DE

SC

RIP

TIO

N

IMPL- TOOL

O&M

GATEKEEPER

MOF

GATEKEEPER

PROC

GATEKEEPER

P & B

GATEKEEPER

PLAN

COMMT

GATEKEEPER

1 2 3 4 5 6

AVG-DURATION

RANGE

STAGES

STG-NAME

TURN-OVER &

ACCEPTANCE

AWARD & NTP

SCHEDULE

MILESTONS

TURN OVER

PHASES

1HOLD

GO

CANCELGATEKEEPER

Project Life (Gate Process)

CFR Report

STAGE 1 STAGE 2 STAGE 3 STAGE 4

Complete Complete Tech

Tech 30% 90% Specs

Category/Contract No./ Description Specs Package Package 100%

Initiated Review Review to Proc't

(1) (30) (90) (3)

standard days 56 98 14

COMMUNITYJUBAIL 1

TECHNICAL

1-06-092-T26 1-Oct-06 P 26-Nov-06 P 10-Dec-06 P 7-Jan-07 P N/A P 10-Jun-07 P 6-Aug-07 P

Engineering Design for Roads 1-Oct-06 A 26-Nov-06 A 10-Dec-06 A 7-Jan-07 A N/A F 10-Jun-07 F 6-Aug-07 F

1-99-101-T15 12-Aug-06 P 7-Oct-06 P 21-Oct-06 P 18-Nov-06 P 13-Jan-07 P 21-Apr-07 P 26-May-07 P

Study and Design of City Center 12-Aug-06 A 7-Oct-06 A 21-Oct-06 A 18-Nov-06 A 13-Jan-07 A 21-Apr-07 F 26-May-07 F

SITE DEVELOPMENT

1-91-709-C12 8-Apr-07 P 3-Jun-07 P 17-Jun-07 P 15-Jul-07 P 28-Oct-07 P 27-Jan-08 P 6-Apr-08 P

Construction of International Residential Area (Phase I) 8-Apr-07 A 3-Jun-07 A 17-Jun-07 A 15-Jul-07 F 28-Oct-07 F 27-Jan-08 F 6-Apr-08 F

1-91-709-C13 9-May-07 P 4-Jul-07 P 18-Jul-07 P 15-Aug-07 P 28-Nov-07 P 27-Feb-08 P 7-May-08 P

Site Development Works in Community Area (Farouk North Area) 9-May-07 A 4-Jul-07 A 18-Jul-07 A 15-Aug-07 F 28-Nov-07 F 27-Feb-08 F 7-May-08 F

1-91-740-C03 9-Aug-07 P 4-Oct-07 P 18-Oct-07 P 15-Nov-07 P 21-Feb-08 P 11-May-08 P 20-Jul-08 P

Rehab and Improvement of Shorelines in all existing Community area 9-Aug-07 A 4-Oct-07 A 18-Oct-07 A 15-Nov-07 F 21-Feb-08 F 11-May-08 F 20-Jul-08 F

IRRIGATION

1-59-575-C27 4-Mar-07 P 29-Apr-07 P 13-May-07 P 10-Jun-07 P 15-Sep-07 P 22-Dec-07 P 17-Feb-08 P

Reinforcement of Community Irrigation System 4-Mar-07 A 29-Apr-07 A 13-May-07 A 10-Jun-07 F 15-Sep-07 F 22-Dec-07 F 17-Feb-08 F

(ABC)

Planning

Committee

Approval

(Start of Eng)

Planning

Committee

Presentation

(PC)

Contract

Initiating

Meeting

(0)

Sea Water Cooling Need

• Heat rejection from industries.

• Cooling media is required to absorb heat

• The System provide Sea Water to be the cooling

media to absorb heat from industries and dissipate

into the Sea.

• The System provides as a proper environmental

control for industries discharge

Feasibility of SWC of Jubail 1

Looking at J 1 , Canal System was Selected

because:• Favorable site location – near Gulf

• Level topography permitting canals

• Ideal arrangement of Industrial Port

Causeway to separate intake from outfall.

SWC System in Jubail 1 ( 1 m m3/hr )

• Sea Water Intake Channel

• Canal System

• Outfall Structure

• Industries Off-Take Structures and Laterals Pipes

• Inverted Siphons between canals segments

• 3 Canals segments with 3 Compartments ( Supply ,

Supply / Return , Return )

• Pump Station

Intake Channel & Pump Station

Canal System

Canal 1

Canal 3

Canal 2

Pump

Station

Outfall

SUPPLY

STRUCTURE

RETURN

STRUCTURE

FLOW MEASUREMENT

CHAMBER

LATERAL PIPELINESEAWATER TO

USER INDUSTRY

ACCESS

BRIDGE

S S/R R

Off-Take Structure

Outfall

Click to edit Master title style

-----194TH Planning Stage

PRODUCTION

CAPACITY

(KTPY)

NO. OF

INDUSTRIES

Lots

COMPLETION

DATE

PRIVATE

INVESTMENT

(SR BILLION)

GOVERNMENT

INVESTMENT

(SR BILLION)

AREA

(KM2)STAGES

49,0001424016.081TOTAL

24,00072009825.0191ST

13,00032011806.3202ND

12,00042013784.7233RD

JUBAIL 2

Feasibility of Jubail 2

For J 2 many option were studies

• Cooling Ponds required large space.

• Canal for once through found not feasible due

to location and crossing KRT and topography

( + 7 m E-W , + 3 N-S )

• Dry cooling , High cost and not in large scale.

• Make Up water for Cooling Towers found most

feasible.

• Advanced technology of using Gases such as

Ammonia. Limited to small scale

Make Up Concept For J 2

Q m = ( 6 – 10 % ) Q rec

Industries fence

Hot Process

Fluid

Sea Water

Blow Down

Q b

Heat

Exchanger

Q m = Q b + Loss

Cold Process

Fluid

Fill

Sea Water

Make Up

Q m

P

Air Q rec

Industries fence

Cooling Towers

Fan Assisted Natural Draft

Mechanical Draft

20 % Convective Heat

Transfer

80 % Evaporative Cooling, Mass Transfer ( 1.5 % Loss of water )

Heat rejection device

Scope of SWC System for J 2

• 200,000 m3/hr Pump station (4 + 2 Pumps)

50,000 m3/hr each , 23 m head , 4 MW

• 5 Pipes configuration ( 2 S , 1 S/R , 2 R )

• Distribution Manifolds

• Headwork and demolish end of canal 2

EXISTING SWC

CANAL 2

SWC PUMP STATION

Stage 1Stage 2Stage 3

KRT

12.0 km.

Overall System

Headwork : Cofferdam

Headwork : Demolish

Headwork : Rebuild

ME

TE

RIN

G

CH

AM

BE

R

STAFF/CONTROL

BUILDING

GUARD

HOUSE

SWITCHGEAR

BUILDING

HYPOCHLORITE

GENERATION BUILDING

TRANSFORMER

T-601

115/13.8kV

37.5/50MVA

TRANSFORMER

T-602

115/13.8kV

37.5/50MVA

FUTURE

FUTURE

FUTURE

FUTURE

SAMPLING

BLDG.

PW/FW TANK FUTURE

FUTURE

SEC

BUILDING

ME

TE

RIN

G

CH

AM

BE

R

J 2 Pump House Layout

R

R

S/R

S

S

S/R

CU

RT

AIN

W

AL

L

FLOW STRAIGHTENING

INCLINED BAR SCREEN

L.W.L. (MIN.)

EL +5.75m RCD

MOTORIZED

BUTTERFLY VALVE

HYDRAULIC OPERATED

BUTTERFLY VALVE

TRAVELING

BRIDGE CRANE

SWC

PUMP

MOTOR

H.W.L.

EL +8.60m RCD

15 TON CRANE HOIST

TRAVELING

BRIDGE CRANE

TRAVELING

BRIDGE CRANE

50 TON CRANE HOIST

15 TON CRANE HOIST

TRASH RACK

J 2 Pump House Section

J 2 Pump House Construction

Piping

• 4 m for East West Piping 55 km

• 3 m for North South Laterals 21 km

• 2 m for industry

connection

• Valves 4 m ( 31) /

3m (21 ) / 2m ( 66)

M

M

M

M

M M

M

M

M

Stage 1Stage 2

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

MM

M

M

M

M

M

Stage 3

P S

End of Canal 2 End of Canal 2

P S

Piping Configuration

KRT Area

Under Aramco Pipes

At Stage 1 , Air-Vent valve 500mm

Manifold 3 D

EN

Below

Ground

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

Manifold

Trenching Detail

FINAL SURFACE ELEVATION

CLASS 1

BEDDING MATERIAL

CLASS 1

BACKFILL MATERIAL

WARNING

TAPE (TYP)

CLASS 2

BACKFILL MATERIAL

TYPICAL TRENCH FOR 5 - DN 4000 SWC PIPES

UNPAVED AREAS

4000 3000 4000 3000 4000 3000 4000 3000 4000

290070007000700070002900

900

900

2350

Industry Connection

INDUSTRY

LIMIT

RC LIMIT

SWC RETURN PIPELINE

SWC SUPPLY PIPELINE FT

TYPICAL INDUSTRY

SEA WATER RETURN TANK

FROM INDUSTRY

SEA WATER RETURN

INDUSTRY CONNECTION DETAIL

INDUSTRY

M

MM

M M

M

M

M

SWC SUPPLY/

RETURN PIPELINE

ANALYZERS

M

SWC - EPC Schedule

Start Finish Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

Stage 1 - 31 March 2009 Engineering

136-C01 Infrastructure in Zone A for Stage 1 of Jubail 2 10-Nov-03 30-Jan-08Procurement

262-C02 KRT Crossing: Underground Infrastructure Part 1 24-May-03 12-Dec-07Construction

065-C45 Infrastructure of Stage 1, P1, J2 (SWC) 04-Aug-05 A 11-Apr-09 Initial Acceptance

072-C31R SWC Pumping Station in Jubail 1 28-Mar-04 A 25-Jul-09

Stage 2 - 31 December 2010

065-C46 Infrastructure of J2 - Stg2 Ph2 (SWC) 09-Feb-06 A 21-Feb-11

Stage 3 - 31 December 2012

065-C48 Infrastructure of Jubail 2 - Stage 3 SWC 24-Jan-07 A 10-Jan-12

Stage 4

065-C51 Infrastructure of Jubail 2 - Stage 4 (SWC) 29-Nov-07 A 20-Jul-13

Data Date 30Nov07 Stage 1 Stage 2 Stage 3

Complete

Demobilization

Target Target

2004 2005

Target

Jubail 2 2012 20132008 2009 2010 201120072006

Thank you