You are on page 1of 68

EXECUTIVE MANAGEMENT SAFETY REVIEW

APRIL 9, 2007
RABIGH
OUTLINE

• INTRODUCTION
• PROGRAM SCOPE AND PROGRESS
• LOGISTICS AND CONTROL
• SAFETY PERFORMANCE
• ENVIRONMENTAL COMPLIANCE
• COMMISSIONING CHALLENGES
• SUMMARY
A 50/50 Joint Venture between Saudi Aramco and Sumitomo
Chemicals, established to build and operate a world class,
integrated refining and petrochemicals complex in Rabigh with
commercial operation in 3Q 2008.

The Rabigh complex will be a Platform for a major industrial


park for conversion industries aimed to benefit the local
economy.
COMPLEX CONFIGURATION
EPPE 250 KTA

95 MMSCFD 1,250 KTA LLDPE 350 KTA


ETHANE ETHYLENE 300 KTA
ETHANE HDPE
CRACKER PP-1 350 KTA
400MBD
900 KTA PP-2 350 KTA
CDU
PROPYLENE PO 200 KTA

C2/C3
9 MBD
EO/EG 600 KTA
BUTANE

MIXED C4
205MBD 120 MBD 92 MBD C4
COMPLEX
VDU VGOHT HOFCC GASOLINE 60 MBD

DIESEL 99 MBD

FUEL OIL 89 MBD


REFINING PLANTS

HPU CT - 2
VDU
VGO - HT SS022

SS025
C4
SRU1 ARU2 SWS2 ALKY
UNIT
SRU2 ARU3 SWS3

ISOM
C4
ACID
PLANT
OLEFIN PLANTS

HOFCC

T&I SS 21 & 24

TANKAGE
AREA
ETHANE
CRACKER
CT - 3
POLYMER PLANTS

PP-1

PP-2
OPEN
PRODUCT LAB/
STORAGE CCR2
WAREHOUSE
AREA
PE’s

Butene-1

HDPE
MONOMER PLANTS

CCR1

MEG PO
UNIT UNIT

INCINERATOR CT - 4 ASU
IWSP / DESALINATION

IWSPP

DESALINATION PLANT
AREA
INDICATIVE QUANTITIES
ITEM QUANTITY
ENGINEERING MH 7 Million
CONSTRUCTION MH 130 Million
EQUIPMENT 7,500
CONCRETE 600,000 M3

STRUCTURAL STEEL 97,000 TONS


PIPING WEIGHT 124,000 TONS
PIPING (Inch Dia) 7,620,000
CABLES 21,250 KM
TRAYS 700 KM
Hardwired PCS I/O 55,000
MAIN PACKAGES
Uitilities-Offsites-1
TANKAGE
Interconnecting
REFINING
MONOMER
OLEFIN
POLYMER
Support Utilities
PLANTS
PLANTS
PLANTS
IWSPP
Facilities

MHI

AL-SUWAIDI
AL-BINALI
NESMA
TEKFEN
TEKFEN
MMG
ATCC
CCC
AL-SUWAIDI
GAMA
FAFCO
SOJITZ
SINOPEC
USTAY
KETTANEH
ATCO
CCE
SPIG
DESCON
CAT
AL-SUWAIDI
OLAYAN
GDTSA
SOJITZ
TECHNOLOGY LICENSORS
EPPE
ETHANEVGOHT
CRACKING
SULFURIC ACID
SULFUR HDPE
MEG
ALKYLATION
RECOVERY
LLDPE
ISOMERIZATION
HIGH OLEFIN FCC
PP-1
BUTENE-1
PP-2
PO
PROGRESS LEVEL
0% 50% 100%

95%
ENGINEERING
96%

83%

PROCUREMENT
87%

25%

CONSTRUCTIO
N 27%

60%

OVERALL
63%

PLAN ACTUAL
DIRECT MANPOWER

35,000
2006 2007 2008

30,000
25,000
20,000
ACTUAL
15,000 PLANNED

10,000
5,000
0
1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q
LOGISTICS

PARTICULAR COUNT

SHIPS ARRIVED 38 / 85
CARGO UNLOADED 58,000 TONS
HEAVY HAUL MOVEMENTS TO DATE 525
MAJOR EQUIPMENT LIFTS TO DATE 82
AVERAGE DAILY TRAFFIC : TRUCKS 2000
: VEHICLES 4900
NUMBER OF CRANES EMPLOYED 240 / 400
LOGISTICS

PARTICULAR COUNT

SHIPS ARRIVED 38 / 85
CARGO UNLOADED 58,000 TONS
HEAVY HAUL MOVEMENTS TO DATE 525
MAJOR EQUIPMENT LIFTS TO DATE 82
AVERAGE DAILY TRAFFIC : TRUCKS 2000
: VEHICLES 4900
NUMBER OF CRANES EMPLOYED 240 / 400
LOGISTICS

PARTICULAR COUNT

SHIPS ARRIVED 38 / 85
CARGO UNLOADED 58,000 TONS
HEAVY HAUL MOVEMENTS TO DATE 525
MAJOR EQUIPMENT LIFTS TO DATE 82
AVERAGE DAILY TRAFFIC : TRUCKS 2000
: VEHICLES 4900
NUMBER OF CRANES EMPLOYED 240 / 400
LOGISTICS

PARTICULAR COUNT

SHIPS ARRIVED 38 / 85
CARGO UNLOADED 58,000 TONS
HEAVY HAUL MOVEMENTS TO DATE 525
MAJOR EQUIPMENT LIFTS TO DATE 82
AVERAGE DAILY TRAFFIC : TRUCKS 2000
: VEHICLES 4900
NUMBER OF CRANES EMPLOYED 240 / 400
LOGISTICS

PARTICULAR COUNT

SHIPS ARRIVED 38 / 85
CARGO UNLOADED 58,000 TONS
HEAVY HAUL MOVEMENTS TO DATE 525
MAJOR EQUIPMENT LIFTS TO DATE 82
AVERAGE DAILY TRAFFIC : TRUCKS 2000
: VEHICLES 4900
NUMBER OF CRANES EMPLOYED 240 / 400
LOGISTICS
Gate 10
Gate 1

RO/RO Gate 5
CONTROL MEASURES

• Established Logistics & Interface Division


• Regular Health and Safety Compliance Checks for all
Construction Camps
• Ambulances and Medical Facilities at various construction
locations
• Emergency Response Plan in place in coordination with
Saudi Aramco Emergency Services
SAFETY TARGET

SAFETY TARGETS

UPPER LIMITS
SAFETY PERFORMANCE

TOTAL MH WORKED 38,000,000


LOST TIME INCIDENTS 4
RECORDABLE CASES 30
MOTOR VEHICLE ACCIDENTS 42

0.02 0.17
ENVIRONMENTAL CONTROL MEASURES

• Installation of high efficiency Sulfur Recovery (99.2%)


• FGD on new fuel oil-fired Power Plant Boilers
• Gas firing for existing Boilers and Process Heaters
• Selection of Low / Ultra low NOx burners for all new units
• Stack gas monitoring and ambient air quality monitoring
• Upgrading Waste Water Treatment Plant
• Treatment of discharged water at harbour to minimise impact
on coral reef
COMMISSIONING

55,000 PCS I/O’s


2,200 Systems
22762,000
7,500
6,600
Process
40,000 X-Rays
Equipment
Hydrotests
LOOPPlants
TESTS
(Partial MCC)
250,000 TEST STEPS
COMMISSIONING

JANUARY
MARCH
JUNE
SEPTEMBER
NOVEMBER
DECEMBER
FEBRUARY
OCTOBER
AUGUST
APRIL
APRIL
JULY
MAY
MAY
2008
2007

SW INTAKE
110 UTILITIES
KV SYSTEM
FO
ETHANE
SYSTEM
HOFCCCRACKER
CDU/HDS
POLYMER
REFINING TO IWSP
REVAMP
/PLANTS
PLANTS
MEG
PLANTS
ENERGIZED
SS 30/40 ENERGIZED
SUMMARY

• PetroRabigh is the largest project of its kind built at one time

• Massive Logistics and Coordination activities

• Large resources needed for Safe Plant Commissioning

• In compliance with strict environmental regulations

• On Target to achieve Commercial Operation by October 2008


CONSTRUCTION PHOTOS
Rabigh Area (Scenario N1)
7th Highest predicted 24-hour average SO2 ground level concentration (in µg/m³)

World Bank Guideline is 125 µg/m³


PME Standard is 365 µg/m³

0 m 5 0 0 0 m1 0 0 0 0 1 m5 0 0 0 2 m0 0 0 0 m 0 m 5 0 0 0 m1 0 0 0 0 1 m5 0 0 0 2 m0 0 0 0 m

(Before the Project) (After the Project)


Rabigh Area (Scenario N1)
Highest predicted 24-hour average NOX ground level concentration
(in µg/m³)

World Bank Guideline is 150 µg/m³


No PME Standard

0 m 5 0 0 0 m1 0 0 0 0 1 m5 0 0 0 2 m0 0 0 0 m 0 m 5 0 0 0 m1 0 0 0 0 1 m5 0 0 0 2 m0 0 0 0 m

(Before the Project) (After the Project)


CONSTRUCTION HSE
INCIDENTS CLASSIFICATION

Incident Classification
Causes/Phenomena
Motor Vehicle
167 LostCaught/Hit
Work Injury
Heat Work Injury
Restrict
55
Crane
Medical Tretment
33 FirstFall'g
Aid Obj
69 Excavation
Asset
5 20 3 35 Fire
Near Miss
Others
42
18

8 9 13
10