jurong rock caverns - awards.ita-aites.org · phase 1 development 2007: started construction of...

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


Stakeholders

Developer

JTC Corporation

Project Management Team

Sintef-Tritech-Multiconsult Consortium

BED / Superintending Officer

Geostock (Access Shafts)

Geostock-Jurong Consultants

Consortium (Tunnels & Caverns)


Main Contractors

Sato Kogyo (Access Shafts)

Hyundai Engineering & Construction

(Tunnels & Caverns)

Consultants

Kiso-Jiban Consultants

Parsons Brinckerhoff Singapore

K L Au Consultants

Beca Singapore


JRC is located below the seabed at Banyan Basin,

Jurong Island

Banyan

Basin

Jurong

Island

Phase 1

Banyan

Basin

JRC

Aboveground

Facility


Development of Jurong Rock Caverns


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


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


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.


Layout Plan of Phase 1



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



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)



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


Default.avi


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


Construction of Access Shafts, Tunnels and Caverns

Access Shaft 1

Access Shafts Contractor: Sato Kogyo

Caverns Contractor: Hyundai Engineering and Construction

Access Shaft 3



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



Construction of Tunnels and Caverns using Drill and Blast Method



Construction Challenges: Limitations in the

Sequencing of Underground Works

Use of T-Lift for mucking out and

vehicle movement



Construction Challenges: Limitations in the

Sequencing of Underground Works



Technical Challenges: Geological &

Hydrogeological Risks


• 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


• 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



Movement of Products

Pipelines connecting JAC and JRC

Pipelines to Very Large Crude Carrier Jetty


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



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



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)


Thank You

jurong rock caverns - awards.ita-aites.org · phase 1 development 2007: started construction of...

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