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 : 15

1:4

Industrial Capital Invest.

240

Industrial Capital Invest.

193
RC Capital Invest.

47
JUBAIL 1

RC Capital Invest.

16
JUBAIL 2

Project Life
(Gate Process)
PHASES

STAGES
AVG-DURATION
RANGE

STG-NAME

PLANNING PHASE

STAGE 1

STAGE 2

STAGE 3

STAGE 4

STAGE 5

STAGE 6

2 W
1-3W

2 W
1-3W

24 W
16 - 48 W

16 W
12 - 24 W

4 W
2 - 12 W

104 W
52 - 208 W

CONCEPT

PLAN COMTT

DESIGN

CONTRACTING

APPROVALS

EXCUTION

BREIF SCOPE

BREIF SCOPE

GATE

GATE

KEEPER

WHY DO WE NEED
THE PROJECT

DISCUSS A/E

2W

GATE

KEEPER

DDG

4W

PLAN

COST +- 25 %

COMMT

BUDGET VERIFICATION

RFP

2W

GATE

KEEPER

30% DESIGN

SCHEMATIC DEWG

ROUGH COST

DESCRIPTION

IMPL - PHASE

PROCESS PHASE

VE+ DEPTS REV

2W

90% DESIGN

12 W

P&B

CHAIRMAN

2W

KEEPER

ISSUE FOR BIDS+ 8 W

RC EST

EVALUATION+RECOMMO
3W
NDATION

2W
PARALELL

BOARD

2W

COM

4W

100 % DESIGN
PROJECT NEED

2W

SCHEDULE

MOF
MILESTONS
TURN OVER
TURN-OVER
&
ACCEPTANCE

DEPTS REVIEW + 2 W
PROCESS CICLE
(STGs (3-6))

AWARD & NTP

DG APPROVAL

2D

NEGT BIDDER

3W

TRANSLATION

PROJECT TITLE

CUSTUDY

IMPL- TOOL

GO

HOLD
CANCEL

GATE
KEEPER

PROJECT SPONSOR

TO BE PREPARED BY
REQUESTER THRU
AFORMAT
FORM - A

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

GATE
KEEPER

KEEPER

MOF

PROC

GATE

PROJECT SPONSOR

PROCURMT- DEPT

PROCURMT DEPT

REVISED

REVISED

REVISED

CFR

CFR

CFR

CONST/ENG

CONST/ENG

O&M

CFR Report
STAGE 1

Category/Contract No./ Description

Contract
Initiating
Meeting
(0)

STAGE 2
Planning
Committee
Presentation
(PC)

STAGE 3
Planning
Committee
Approval
(Start of Eng)
(ABC)

Tech
Specs
Initiated
(1)

standard days

Complete
30%
Package
Review
(30)
56

Complete
90%
Package
Review
(90)
98

Tech
Specs
100%
to Proc't
(3)
14

COMMUNITY
JUBAIL 1
TECHNICAL
1-06-092-T26

1-Oct-06 P

26-Nov-06 P

10-Dec-06

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

7-Jan-07 A

N/A F

10-Jun-07 F

6-Aug-07 F

12-Aug-06 P
12-Aug-06 A

7-Oct-06 P
7-Oct-06 A

21-Oct-06
21-Oct-06

P
A

18-Nov-06 P
18-Nov-06 A

13-Jan-07 P
13-Jan-07 A

21-Apr-07 P
21-Apr-07 F

26-May-07 P
26-May-07 F

1-91-709-C12
Construction of International Residential Area (Phase I)

8-Apr-07 P
8-Apr-07 A

3-Jun-07 P
3-Jun-07 A

17-Jun-07
17-Jun-07

P
A

15-Jul-07 P
15-Jul-07 F

28-Oct-07 P
28-Oct-07 F

27-Jan-08 P
27-Jan-08 F

6-Apr-08 P
6-Apr-08 F

1-91-709-C13
Site Development Works in Community Area (Farouk North Area)

9-May-07 P
9-May-07 A

4-Jul-07 P
4-Jul-07 A

18-Jul-07
18-Jul-07

P
A

15-Aug-07 P
15-Aug-07 F

28-Nov-07 P
28-Nov-07 F

27-Feb-08 P
27-Feb-08 F

7-May-08 P
7-May-08 F

1-91-740-C03
Rehab and Improvement of Shorelines in all existing Community area

9-Aug-07 P
9-Aug-07 A

4-Oct-07 P
4-Oct-07 A

18-Oct-07
18-Oct-07

P
A

15-Nov-07 P
15-Nov-07 F

21-Feb-08 P
21-Feb-08 F

11-May-08 P
11-May-08 F

20-Jul-08 P
20-Jul-08 F

1-59-575-C27

4-Mar-07 P

29-Apr-07 P

13-May-07

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

10-Jun-07 F

15-Sep-07 F

22-Dec-07 F

17-Feb-08 F

1-99-101-T15
Study and Design of City Center

SITE DEVELOPMENT

IRRIGATION

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

RETURN
STRUCTURE

ACCESS
BRIDGE

FLOW MEASUREMENT
CHAMBER

SEAWATER TO
USER INDUSTRY

LATERAL PIPELINE

S/R

Outfall

JUBAIL 2

Click to edit Master title style

STAGES

AREA
(KM2)

GOVERNMENT
INVESTMENT
(SR BILLION)

PRIVATE
INVESTMENT
(SR BILLION)

COMPLETION
DATE

NO. OF
INDUSTRIES
Lots

PRODUCTION
CAPACITY
(KTPY)

1ST

19

5.0

82

2009

24,000

2ND

20

6.3

80

2011

13,000

3RD

23

4.7

78

2013

12,000

4TH

19

TOTAL

81

16.0

14

49,000

Planning
Stage-

240

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
Hot Process
Fluid

Qb
Fill

Air

Sea Water
Make Up

Q rec

Heat
Exchanger

Qm

Industries fence

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

Cold Process
Fluid

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

Fan Assisted Natural Draft

Mechanical 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

SEC
BUILDING

FUTURE

FUTURE
SWITCHGEAR
BUILDING

TRANSFORMER
T-601
115/13.8kV
37.5/50MVA

FUTURE

FUTURE

GUARD
HOUSE
STAFF/CONTROL
BUILDING
PW/FW TANK

FUTURE

S
S

S/R
METERING
CHAMBER

FUTURE

S/R

R
R

METERING
CHAMBER

SAMPLING
BLDG.

J 2 Pump House Section

TRAVELING
BRIDGE CRANE
50 TON CRANE HOIST

TRAVELING
BRIDGE CRANE

SWC
PUMP
MOTOR
15 TON CRANE HOIST
TRAVELING
BRIDGE CRANE

TRASH RACK

15 TON CRANE HOIST

HYDRAULIC OPERATED
BUTTERFLY VALVE

CURTAIN WALL

MOTORIZED
BUTTERFLY VALVE

FLOW STRAIGHTENING
INCLINED BAR SCREEN

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

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

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
N

M
M

Below
Ground

Manifold

Trenching Detail

3000

4000

3000

4000

3000

4000

3000

4000 900

WARNING
TAPE (TYP)

900

FINAL SURFACE ELEVATION

CLASS 2
BACKFILL MATERIAL
2350

4000

CLASS 1
BACKFILL MATERIAL
2900

7000

7000

7000

7000

2900

TYPICAL TRENCH FOR 5 - DN 4000 SWC PIPES

UNPAVED AREAS

CLASS 1
BEDDING MATERIAL

Industry Connection
TYPICAL INDUSTRY
SEA WATER RETURN TANK

RC LIMIT

INDUSTRY
LIMIT
SEA WATER RETURN
FROM INDUSTRY

ANALYZERS

SWC RETURN PIPELINE

M

INDUSTRY

SWC SUPPLY/
RETURN PIPELINE
M

FT

SWC SUPPLY PIPELINE

INDUSTRY CONNECTION DETAIL

SWC - EPC Schedule

Jubail 2

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

Stage 1 - 31 March 2009

Engineering

136-C01 Infrastructure in Zone A for Stage 1 of Jubail 2

10-Nov-03

30-Jan-08

262-C02 KRT Crossing: Underground Infrastructure Part 1

24-May-03 12-Dec-07

065-C45 Infrastructure of Stage 1, P1, J2 (SWC)

04-Aug-05 A 11-Apr-09

072-C31R SWC Pumping Station in Jubail 1

28-Mar-04 A 25-Jul-09

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