Singapore – 11 November 2016
Jurong Rock Caverns
Development of Underground Rock
Caverns for Storage of Liquid
Hydrocarbons on Jurong IslandEr. Teo Tiong Yong
Jurong Rock Caverns – Er. Teo Tiong Yong
Singapore – 11 November 2016
Stakeholders
Developer
JTC Corporation
Project Management Team
Sintef-Tritech-Multiconsult Consortium
BED / Superintending Officer
Geostock (Access Shafts)
Geostock-Jurong Consultants
Consortium (Tunnels & Caverns)
Jurong Rock Caverns – Er. Teo Tiong Yong
Main Contractors
Sato Kogyo (Access Shafts)
Hyundai Engineering & Construction
(Tunnels & Caverns)
Consultants
Kiso-Jiban Consultants
Parsons Brinckerhoff Singapore
K L Au Consultants
Beca Singapore
Singapore – 11 November 2016
JRC is located below the seabed at Banyan Basin,
Jurong Island
Banyan
Basin
Jurong
Island
Phase 1
Banyan
Basin
JRC
Aboveground
Facility
Jurong Rock Caverns – Er. Teo Tiong Yong
Development of Jurong Rock Caverns
Singapore – 11 November 2016
Storage in
aboveground
tanks
Storage in
underground
rock caverns
60 Ha of surface
land freed up
Aboveground land used for production; underground land used for storage
Underground Rock Caverns for Oil
Storage
• Creating a competitive advantage
• Saving surface land
• Improved security
• Improved health & safety
Singapore – 11 November 2016
Jurong Rock Caverns Journey
Site Investigation Access Shaft Construction Tunnel Excavation
6
2006: Funding approval obtained for Phase 1 development
2007: Started construction of access shafts
2009: Started construction of main caverns
2Q 2014: Completion of 1st two caverns to serve JAC
1Q 2017: Completion of Jurong Rock Caverns
Engineering Design of Access Shafts
Feasibility & Business Studies, Soil Investigation and Funding
Approval
2006 2007 20092001 2Q2014 2017
Construction of Main Caverns
Construction of Access Shafts & Engineering
Design of Main Caverns
Completed Cavern
Singapore – 11 November 20167
Overall Development of JRC
JURONG ISLAND
Access Shaft 1
Access Shaft 3
3.2 ha
Multi-purpose Product Jetty
Phase 1 & 2 = 30 Ha
Phase 1
Caverns Notation ProductCavern Storage
Volume (m3)
Cavern 1 Crude Oil, Condensate
1 x 150,000
Caverns 2 to 5 4 x 330,000
Total Storage Volume (m3) 1,470,000
*Condensate is a hydrocarbon liquid for production of aromatics which in turn is used to make fabric and plastic.
Singapore – 11 November 2016
Layout Plan of Phase 1
Jurong Rock Caverns – Er. Teo Tiong Yong
Singapore – 11 November 2016
Cross Section of Shafts, Tunnels &
Caverns
Access Shaft 3
Oil, Seepage Water Pump
Sump
Maintenance Chamber
Banyan Basin
Operation Tunnels
Oil Storage Cavern
Access Shaft 1
132m belowground
Access Tunnels
Jurong Rock Caverns – Er. Teo Tiong Yong
Singapore – 11 November 2016
Typical Cross Section of a Cavern Gallery
27
m20m
• 9 storeys high (27 m)
• Length = 340 m
• Excavation using drill and blast
method with grouting (if
required)
• Volume per storage cavern =
165,000m3
(two typical storage tanks of
80,000m3 capacity)
Jurong Rock Caverns – Er. Teo Tiong Yong
Singapore – 11 November 2016
Technical Innovation:
How Does the Underground Oil Storage
Work?
• Our Caverns are unlined
• Caverns roofs are below
groundwater table
• Water pressure keeps oil
within the caverns
• Water that seeps in is
collected and pumped up
automatically
Jurong Rock Caverns – Er. Teo Tiong Yong
Singapore – 11 November 2016
How deep
is Jurong
Rock
Caverns?
10m
20m
30m
40m
50m
60m
70m
80m
90m
100m
110m
120m
130m
140m
150m
Jurong
Rock
Caverns
MRT System
Singapore Power Cable
Tunnel
Deep Tunnel Sewerage System
Underground Expressways,
Underpasses & Shopping Malls
Singapore – 11 November 2016
Construction of Access Shafts, Tunnels and Caverns
Access Shaft 1
Access Shafts Contractor: Sato Kogyo
Caverns Contractor: Hyundai Engineering and Construction
Access Shaft 3
Jurong Rock Caverns – Er. Teo Tiong Yong
Singapore – 11 November 2016
ACD-21m
ACD-23m 2m
4.7
m
21.5m
23.9m
10.7m 10.7m
400mm Skin Wall
by others
DIAPHGRAM WALL
t=1.0mRC RING BEAM
1.0mx1.0m
RC RING BEAM1.0mx1.5m
CAPPING BEAM
ACD-48m
ACD -126.025m
ACD -93.525 m
ACD -86.300 m
18.3m
20.55m
34.4m
9400
46
100/26
62 18 4IIIIV>16
100
60
50
100
100
68
48
96
18
9
45
54
39
25
43
18
4
15
18
15
6
III10
43 19 0
28 6 0
44 13 0
100 87 77
100 69 52
100 74 54
100 95 93
100 100 93
IIIIV10
III
V>16
IIIII
13II
III12IIIII
>16II
III>16
IIIII
>16IIIII
>16II
>16III5IIIII10
II III11
I5
I2
100 100 100I
<1
100 95 85III
100 100 100I
<1I0
100 97 78
100 96 86
100 100 100
100 87 60
100 96 96
100 100 100
100 100 100
100 100 98
100 88 88
100 100 95
100 100 100
100 100 100
I4
I5
I1
I8
I4I0I0
I
1to2I
<1
I0I
<1
I
I
2
RECLAIMED
SAND
FINE TO
COARSE SAND
CLAYEY
SILT
(JURONG
FORMATION)
SILTSTONE
AND
SANDSTONE
(JURONG
FORMATION)
28m
100 100 100
-75.5
I
<1100 100 100
100 100 100
4m
4m
4m
4m
3.7
2m
CL 35
Section D
RL103.259 = ACD +5.0mEXTG. Ground Level RL103.300 =
ACD +5.041m
DE
PT
H
N-V
AL
UE
TC
R
WG
& F
I
m %BL
OW
S/3
0C
M
SC
R
%
RQ
D
%
-1.5
-3.0
-6.0
-9.0
-12.0
-15.0
-18.0
-21.0
-24.4
-27.0
-27.7
-30.7
-33.7
-36.4
-37.6
-39.5
-42.4
-45.4
-48.4
-50.0
-53.0
-54.3
-56.0
-57.5
-60.5
-63.5
-66.5
-69.5
-72.5
-78.5
-81.0
-83.0
-84.5
-86.5
-89.0
-90.5
-93.5
-96.5
-99.5
-102.5
-104.0
-105.5
12
13
6
9
22
41
ACD -86.000 m
ACD-55m CL 34
CL 33
CL 32
CL 31
CL 30
CL 29
CL 28
CL 27
CL 26
CL 25
CL 24
CL 23
CL 22
CL 21
CL 20
CL 19
CL 18
CL 25
CL 24
CL 23
CL 22
CL 21
CL 20
CL 19
CL 18
CL 17
CL 16
CL 15
CL 14
CL 13
CL 12
CL 11
CL 10
CL 9
CL 8
CL 7
CL 6
CL 5
CL 4
CL 3
CL 2
CL 1
Section E
Section F
CL 1
CL 2
CL 3
CL 4
CL 5
CL 6
CL 7
CL 8
CL 9
CL 10
CL 11
CL 12
CL 13
CL 14
CL 15
CL 16
CL 17
CL 18
CL 19
CL 20
CL 21
CL 22
CL 23
CL 24
CL 25
CL 18
CL 19
CL 20
CL 21
CL 22
CL 23
CL 24
CL 25
CL 26
CL 27
CL 28
CL 29
CL 30
CL 31
CL 32
CL 33
CL 34
CL 35
32m
131m
Typical Cross Section
Fine to Coarse
Sand
Siltstone and
Sandstone
(Jurong
Formation)
Siltstone and
Sandstone
(Jurong
Formation)
Clayey Silt
(Residual Jurong
Formation)
Reclaimed Sand
ACD -86.000 m
ACD-55m CL 34
CL 33
CL 32
CL 31
CL 30
CL 29
CL 28
CL 27
CL 26
CL 25
CL 24
CL 23
CL 22
CL 21
CL 20
CL 19
CL 18
CL 25
CL 24
CL 23
CL 22
CL 21
CL 20
CL 19
CL 18
CL 17
CL 16
CL 15
CL 14
CL 13
CL 12
CL 11
CL 10
CL 9
CL 8
CL 7
CL 6
CL 5
CL 4
CL 3
CL 2
CL 1
4.7
m4m
4m
4m
4m
3.7
2m
CL 35
Section D
Section E
Section F
RL103.259 = ACD +5.0mEXTG. Ground Level RL103.300 =ACD +5.041m
DE
PT
H
N-V
AL
UE
TC
R
WG
& F
I
m %BL
OW
S/3
0C
M
SC
R
%R
QD
%
-1.5
-3.0
-6.0
-9.0
-12.0
-15.0
-18.0
-21.0
-24.4
-27.0
-27.7
-30.7
-33.7
-36.4
-37.6
-39.5
-42.4
-45.4
-48.4
-50.0
-53.0
-54.3
-56.0
-57.5
-60.5
-63.5
-66.5
-69.5
-72.5
-78.5
-81.0
-83.0
-84.5
-86.5
-89.0
-90.5
-93.5
-96.5
-99.5
-102.5
-104.0
-105.5
12
13
6
9
22
41
46
100/26
62 18 4IIIIV
>16
100
60
50
100
100
68
48
96
18
9
45
54
39
25
43
18
4
15
18
15
6
III
10
43 19 0
28 6 0
44 13 0
100 87 77
100 69 52
100 74 54
100 95 93
100 100 93
III
IV
10
III
V>16
IIIII
13II
III
12II
III
>16IIIII
>16
IIIII
>16II
III
>16II
>16III
5II
III10
II III
11
I
5
I2
100 100 100I
<1
100 95 85 III
100 100 100I
<1I0
100 97 78
100 96 86
100 100 100
100 87 60
100 96 96
100 100 100
100 100 100
100 100 98
100 88 88
100 100 95
100 100 100
100 100 100
I4
I5
I1
I8
I4I0I0
I1to2
I<1
I0I
<1
I
I2
RECLAIMED
SAND
FINE TO
COARSE SAND
CLAYEYSILT
(JURONG
FORMATION)
SILTSTONE
AND
SANDSTONE(JURONG
FORMATION)
28m
100 100 100
-75.5
I<1100 100 100
100 100 100
ACD-21m
ACD-23m 2m
CL 1
CL 2
CL 3
CL 4
CL 5
CL 6
CL 7
CL 8
CL 9
CL 10
CL 11
CL 12
CL 13
CL 14
CL 15
CL 16
CL 17
CL 18
CL 19
CL 20
CL 21
CL 22
CL 23
CL 24
CL 25
CL 18
CL 19
CL 20
CL 21
CL 22
CL 23
CL 24
CL 25
CL 26
CL 27
CL 28
CL 29
CL 30
CL 31
CL 32
CL 33
CL 34
CL 35
21.5m
23.9m
10.7m 10.7m
400mm Skin Wall
by others
DIAPHGRAM WALL
t=1.0mRC RING BEAM1.0mx1.0m
RC RING BEAM1.0mx1.5m
CAPPING BEAM
ACD-48m
131m
32m
ACD -126.025m
ACD -93.525 m
ACD -86.300 m
18.3m
20.55m
34.4m
9400
Construction of Access Shafts
Diaphragm Wall with Ring Beams
Concrete Lining
Shotcrete and Rock Bolts
Jurong Rock Caverns – Er. Teo Tiong Yong
Singapore – 11 November 2016
Construction of Tunnels and Caverns using Drill and Blast Method
Jurong Rock Caverns – Er. Teo Tiong Yong
Singapore – 11 November 2016
Construction Challenges: Limitations in the
Sequencing of Underground Works
Use of T-Lift for mucking out and
vehicle movement
Jurong Rock Caverns – Er. Teo Tiong Yong
Singapore – 11 November 2016
Construction Challenges: Limitations in the
Sequencing of Underground Works
Jurong Rock Caverns – Er. Teo Tiong Yong
Singapore – 11 November 2016
Technical Challenges: Geological &
Hydrogeological Risks
Singapore – 11 November 2016
• Venturing so deep underground in sedimentary rock is breaking new
ground
• Unpredictable geological conditions
• Adopting systematic deep investigation boreholes and probe holes.
• Pre-grouting to reduce groundwater seepage
• Continual probing and site investigation before excavation
• Pre-grouting to reduce groundwater seepage
• Adapt excavation methods to site conditions
Technical Challenges:
Geological & Hydrogeological Risks
Singapore – 11 November 2016
• Explosives Storage Houses (ESH) were constructed to
have 24hours/7days access to explosives for excavation
works to improve construction productivity
Technical Innovation:
Use of Explosives
Jurong Rock Caverns – Er. Teo Tiong Yong
Singapore – 11 November 2016
Movement of Products
Pipelines connecting JAC and JRC
Pipelines to Very Large Crude Carrier Jetty
Singapore – 11 November 2016
Overview of Aboveground Facilities
Administration
Building
Valve Manifold Area
Pipe Rack
& Pipes
Export Booster
Pump & Metering
Area
Wastewater
Treatment PlantVapour
Recovery Unit
Pipe Rack
& Pipes
Jetty
Jurong Rock Caverns – Er. Teo Tiong Yong
Singapore – 11 November 2016
Status of JRC Project
Caverns 1 and 2• Construction of caverns completed in Aug 2013• Construction of supporting facilities completed in Mar 2014• Testing and commissioning from Apr 2014• Started operations for Jurong Aromatics Corporation on 1 Jul 2014
Caverns 3, 4 and 5• Construction of caverns completed in Jun 2014• Construction of supporting facilities completed in early 2016• Testing & Commissioning currently on-going
Jurong Rock Caverns – Er. Teo Tiong Yong
Singapore – 11 November 2016
ASEAN Outstanding
Engineering Achievement
Awards 2015
IES Prestigious
Engineering Awards 2015SG Mark
Platinum 2015
SPMI – Project of the Year
Award 2015 - 2016
(Engineering & Construction)
Singapore Structural Awards 2014
Commendation Award for Industrial Structures
TOP 50 Engineering Feats @ IES-SG50 (2016)
Jurong Rock Caverns – Er. Teo Tiong Yong
Thank You