ROYAL COMMISSION FOR JUBAIL & YANBU

Sea Water Cooling System For Jubail 2

December 2007

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.

Royal Commission Mission

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.

Achievements ( In Jubail )

Produces 7% of the worlds petrochemicals. Contributes 11.5% of the Kingdoms non-oil GDP.

Creates 70% of the Kingdoms non-oil exports.

Annual growth is sustained at 6%. Jubail has attracted over 50% of the Kingdoms total foreign investment.
Jubail is the Best City in attracting foreign investment, award by Financial Times , 2005

RC & Industrial Sector Capital Investment

( SR Billion)

1:4
Industrial Capital Invest.

1 : 15
Industrial Capital Invest.

193
RC Capital Invest.

240

47
JUBAIL 1

RC Capital Invest.

16
JUBAIL 2

Project Life
(Gate Process)
PHASES

PLANNING PHASE
STAGE 1
2 W 1-3W

PROCESS PHASE

IMPL - PHASE

STAGES
AVG-DURATION RANGE

STAGE 2
2 W 1-3W

STAGE 3
24 W 16 - 48 W

STAGE 4
16 W 12 - 24 W

STAGE 5
4 W 2 - 12 W

STAGE 6
104 W 52 - 208 W

STG-NAME

CONCEPT
BREIF SCOPE ROUGH COST GATE
KEEPER

PLAN COMTT
BREIF SCOPE SCHEMATIC DEWG GATE
KEEPER

DESIGN
DISCUSS A/E 30% DESIGN
PLAN

CONTRACTING
2W 4W 2W RFP 2W

APPROVALS
GATE
KEEPER

EXCUTION
GATE
KEEPER

GATE
KEEPER

CHAIRMAN MOF

2W 2W
PARALELL

AWARD & NTP SCHEDULE

GATE
KEEPER

DESCRIPTION

WHY DO WE NEED THE PROJECT

DDG

COST +- 25 % BUDGET VERIFICATION

COMMT

VE+ DEPTS REV 90% DESIGN

P&B

ISSUE FOR BIDS+ 8 W RC EST

PROC

BOARD COM

2W 4W

MOF
MILESTONS TURN OVER TURN-OVER & ACCEPTANCE

O&M

12 W

EVALUATION+RECOMMO 3W NDATION

DEPTS REVIEW + 2 W PROCESS CICLE (STGs (3-6)) 100 % DESIGN PROJECT NEED PROJECT TITLE TRANSLATION 2W DG APPROVAL NEGT BIDDER 2D 3W

CUSTUDY

PROJECT SPONSOR

PROJECT SPONSOR
TO BE PREPARED BY REQUESTER THRU POWER POINT PRESENTATION FORM -B

PROJECT SPONSOR

PROCURMT- DEPT

PROCURMT DEPT

CONST/ENG

IMPL- TOOL

1
HOLD CANCEL

GO GATE
KEEPER

TO BE PREPARED BY REQUESTER THRU AFORMAT FORM - A

REVISED

REVISED

REVISED

CFR

CFR

CFR

CONST/ENG

CFR Report
STAGE 1
Contract Initiating Meeting (0)

STAGE 2
Planning Committee Presentation (PC) Planning Committee Approval (Start of Eng) (ABC) Tech Specs Initiated (1)

STAGE 3
Complete 30% Package Review (30) 56 Complete 90% Package Review (90) 98 Tech Specs 100% to Proc't (3) 14

Category/Contract No./ Description

standard days

COMMUNITY
JUBAIL 1
TECHNICAL
1-06-092-T26 Engineering Design for Roads 1-99-101-T15 Study and Design of City Center 1-Oct-06 P 1-Oct-06 A 12-Aug-06 P 12-Aug-06 A 8-Apr-07 P 8-Apr-07 A 9-May-07 P 9-May-07 A 9-Aug-07 P 9-Aug-07 A 4-Mar-07 P 4-Mar-07 A 26-Nov-06 P 26-Nov-06 A 7-Oct-06 P 7-Oct-06 A 3-Jun-07 P 3-Jun-07 A 4-Jul-07 P 4-Jul-07 A 4-Oct-07 P 4-Oct-07 A 29-Apr-07 P 29-Apr-07 A 10-Dec-06 10-Dec-06 21-Oct-06 21-Oct-06 17-Jun-07 17-Jun-07 18-Jul-07 18-Jul-07 18-Oct-07 18-Oct-07 13-May-07 13-May-07 P A P A P A P A P A P A 7-Jan-07 P 7-Jan-07 A 18-Nov-06 P 18-Nov-06 A 15-Jul-07 P 15-Jul-07 F 15-Aug-07 P 15-Aug-07 F 15-Nov-07 P 15-Nov-07 F 10-Jun-07 P 10-Jun-07 F N/A P N/A F 13-Jan-07 P 13-Jan-07 A 28-Oct-07 P 28-Oct-07 F 28-Nov-07 P 28-Nov-07 F 21-Feb-08 P 21-Feb-08 F 15-Sep-07 P 15-Sep-07 F 10-Jun-07 P 10-Jun-07 F 21-Apr-07 P 21-Apr-07 F 27-Jan-08 P 27-Jan-08 F 27-Feb-08 P 27-Feb-08 F 11-May-08 P 11-May-08 F 22-Dec-07 P 22-Dec-07 F 6-Aug-07 P 6-Aug-07 F 26-May-07 P 26-May-07 F 6-Apr-08 P 6-Apr-08 F 7-May-08 P 7-May-08 F 20-Jul-08 P 20-Jul-08 F 17-Feb-08 P 17-Feb-08 F

SITE DEVELOPMENT
1-91-709-C12 Construction of International Residential Area (Phase I) 1-91-709-C13 Site Development Works in Community Area (Farouk North Area) 1-91-740-C03 Rehab and Improvement of Shorelines in all existing Community area

IRRIGATION
1-59-575-C27 Reinforcement of Community Irrigation System

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 Pump Station

Canal System

3 Canals segments with 3 Compartments ( Supply , Supply / Return , Return ) Inverted Siphons between canals segments Industries Off-Take Structures and Laterals Pipes Outfall Structure

Intake Channel & Pump Station

Canal System

Canal 3

Pump Station

Canal 1

Canal 2 Outfall

Off-Take Structure
SUPPLY STRUCTURE FLOW MEASUREMENT CHAMBER RETURN STRUCTURE ACCESS BRIDGE

S/R

SEAWATER TO USER INDUSTRY

LATERAL PIPELINE

Outfall

Click to edit Master title style

JUBAIL 2

STAGES

AREA (KM2)

GOVERNMENT INVESTMENT (SR BILLION)

PRIVATE INVESTMENT (SR BILLION)

COMPLETION DATE

NO. OF INDUSTRIES Lots

PRODUCTION CAPACITY (KTPY)

1ST 2ND

19 20

5.0 6.3

82 80

2009 2011

7 3

24,000 13,000

3RD 4TH
TOTAL

23 19
81

4.7
-

78

2013

4
-

12,000
-

Planning Stage

16.0

240

14

49,000

Feasibility of Jubail 2
For J 2 many option were studies
Canal for once through found not feasible due to location and crossing KRT and topography ( + 7 m E-W , + 3 N-S )
Cooling Ponds required large space. Dry cooling , High cost and not in large scale. Advanced technology of using Gases such as Ammonia. Limited to small scale

Make Up water for Cooling Towers found most

feasible.

Make Up Concept For J 2

Sea Water Blow Down

Qb
Fill

Hot Process Fluid

Air

Q rec

Heat Exchanger

Sea Water Make Up

Cold Process Fluid

Qm

Industries fence

Q m = ( 6 10 % ) Q rec Qm=Q b + Loss Industries fence

Cooling Towers
Heat rejection device 20 % Convective Heat Transfer
80 % Evaporative Cooling , Mass Transfer ( 1.5 % Loss of water )
Mechanical Draft

Fan Assisted Natural Draft

Scope of SWC System for J 2

Headwork and demolish end of canal 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

Overall System
12.0 km.

KRT

SWC PUMP STATION

EXISTING SWC CANAL 2

Stage 3

Stage 2

Stage 1

Headwork : Cofferdam

Headwork : Demolish

Headwork : Rebuild

J 2 Pump House Layout

HYPOCHLORITE GENERATION BUILDING TRANSFORMER T-602 115/13.8kV 37.5/50MVA SWITCHGEAR BUILDING TRANSFORMER T-601 115/13.8kV 37.5/50MVA FUTURE SEC BUILDING FUTURE

FUTURE

GUARD HOUSE STAFF/CONTROL BUILDING PW/FW TANK

FUTURE

FUTURE

S S

S/R
METERING CHAMBER
FUTURE

S/R
SAMPLING BLDG.

R R

METERING CHAMBER

J 2 Pump House Section

TRAVELING BRIDGE CRANE 50 TON CRANE HOIST SWC PUMP MOTOR

TRAVELING BRIDGE CRANE

15 TON CRANE HOIST TRAVELING BRIDGE CRANE

TRASH RACK

15 TON CRANE HOIST MOTORIZED BUTTERFLY VALVE HYDRAULIC OPERATED BUTTERFLY VALVE

CURTAIN WALL

H.W.L. EL +8.60m RCD L.W.L. (MIN.) EL +5.75m RCD

FLOW STRAIGHTENING INCLINED BAR SCREEN

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)

Piping Configuration

PS
M M

End of Canal 2

Stage 3

Stage 2

Stage 1

KRT Area

Under Aramco Pipes

At Stage 1 , Air-Vent valve 500mm

Manifold 3 D
M

N
M M M

Below Ground

Manifold

Trenching Detail

4000

3000

4000

3000

4000

3000

4000

3000

4000 900 FINAL SURFACE ELEVATION CLASS 2 BACKFILL MATERIAL CLASS 1 BACKFILL MATERIAL
2350

900

WARNING TAPE (TYP)

2900

7000

7000

7000

7000

2900

CLASS 1 BEDDING MATERIAL

TYPICAL TRENCH FOR 5 - DN 4000 SWC PIPES UNPAVED AREAS

Industry Connection
TYPICAL INDUSTRY SEA WATER RETURN TANK

RC LIMIT

INDUSTRY LIMIT ANALYZERS SEA WATER RETURN FROM INDUSTRY

M

SWC RETURN PIPELINE

M

SWC SUPPLY/ RETURN PIPELINE

M

INDUSTRY

FT

SWC SUPPLY PIPELINE

INDUSTRY CONNECTION DETAIL

SWC - EPC Schedule

Jubail 2
Stage 1 - 31 March 2009
136-C01 Infrastructure in Zone A for Stage 1 of Jubail 2 262-C02 KRT Crossing: Underground Infrastructure Part 1 065-C45 Infrastructure of Stage 1, P1, J2 (SWC) 072-C31R SWC Pumping Station in Jubail 1 10-Nov-03 30-Jan-08 24-May-03 12-Dec-07 04-Aug-05 A 11-Apr-09 28-Mar-04 A 25-Jul-09
2004 Start Finish 2005 2006 2007 2008 2009 2010 2011 2012 2013 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 Engineering Procurement Construction Initial Acceptance Complete Demobilization

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 Target Stage 2 Target Stage 3 Target

Thank you