Fluor is leading the FDH JV, partnering with Daewoo Construction and Engineering and Hyundai Heavy Industries. This JV is also executing the brownfield and greenfield KNPC Clean Fuels MAB2 project at the nearby KNPC Mina Abdullah refinery in Kuwait. FDH JV provided KIPIC with the most competitive lump sum EPC offer for a combination of two packages for the Al-Zour project, thus securing the contract.
Packages 2 and 3 include scope and technology similar to the greenfield MAB2 project, with larger capacity and/or more parallel trains. The scope includes process units, utilities and infrastructure for the new Al-Zour Refinery project.
The contract was signed October 2015. FDH JV will lead the project from the Fluor Amsterdam office, supported by offices in New Delhi, Al Khobar, Kuwait, Houston and Seoul. Sourcing of materials will be global, with a preferential treatment to local suppliers and subcontractors. Peak labor at the site in Kuwait is expected to be 17,000 people.
Large-scale off-site pipe fabrication and a partial modular execution strategy is planned. Module fabrication is taking place at the COOEC-Fluor Heavy Industries Co., Ltd. (COOEC-Fluor) fabrication yard in Zhuhai, China.
Realization of the entire Al-Zour Refinery has been divided by KIPIC into five discrete packages as follows:
Package 1 – Main Process Units (by others)
Package 2 Support Process Units – Includes Hydrogen Recovery Unit (HR), Hydrogen Compression Unit (HC), Hydrogen Production Units (HPU), Sour Water Stripper Unit (SWS), Amine Regeneration Unit (ARU), Sulfur Recovery Units (SRU) and Tail Gas Treating Unit (TGTU), Flare, Sulfur Pelletizing / Conveying, Acid Gas Flare, Sulfur Storage Area
Package 3 Utilities and Offsites – Includes Steam Generation Unit, Air Systems, Water Systems, Cooling Water Unit, EICS & ICSS, HV Substations, Interconnecting Pipe Rack, Wastewater Treating, and a large size campus area with Administration Building, Training Center, Laboratory, Mosque, HSE/Clinic/Fire-brigade, Central Control Room, Supermarket and dozens of refinery support buildings for security, operations and maintenance
Package 4 – Tank Farm (by others)
Package 5 – Marine and Export Facilities (by others)
In May 2018, the first 14 of the project's 188 modules were loaded onto a barge and shipped from the COOEC-Fluor fabrication yard to Kuwait. The module shipment was marked by a ceremony officiated by Hatem Al-Awadhi, KIPIC's deputy chief executive officer, and was attended by executive members of the project team.