ahmed al balawi-sea water cooling system for jubail 2
TRANSCRIPT
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