Saudi Kayan Petrochemical Complex - Water Systems

Client: Saudi Kayan Petrochemical Company

Location: Al Jubail, Saudi Arabia

Business Segment: Energy Solutions

Industry: Fuels

Services: Engineering and DesignProcurementConstruction

Map showing the location of Saudi Kayan Petrochemical Complex - Water Systems

Executive Summary

Fluor was responsible for engineering, procurement and construction management (EPCm) of the utilities and offsites (U&O) scope, approximately 30% of the total project. The U&O scope of work included all water and wastewater systems.

Fluor scope of work for the water and wastewater systems of the Saudi Kayan project included:

Utilities

Water treatment
Storage and distribution
Boiler feedwater
Demineralized water
Fire water
Seawater cooling supply and return
Oily water and storm water treatment

Offsites/Infrastructure

Wastewater treatment
Seawater cooling tower

Offplots

Potable water
Sanitary sewer and industrial waste tie-ins

Client's Challenge

The project was a joint venture between Saudi Basic Industries Corporation and Al-Kayan. Saudi Kayan Petrochemical Company constructed one of the largest petrochemical projects in the world, requiring 140 million work hours with a peak workforce of 40,000.

Fluor's Solution

We provided EPCm services for the U&O scope of the project, approximately 30% of the total project. The water and wastewater components of the project were included in the U&O scope. The engineering on the project was executed by multiple Fluor offices in the U.S., UK, Philippines and Saudi Arabia. Procurement was done on a global basis.

We were responsible for providing utilities such as power, fuel gas, cooling water, instrument air, boilers and flares along with port facilities and third parties such as Aramco. Fluor was also responsible for the site infrastructure and buildings in the administration area.

As with all projects, we developed and implemented our health, safety and environmental (HSE) culture, goals and expectations for the Saudi Kayan project. As a result of everyone's commitment to safe work performance, in May 2009, the Fluor site team and the U&O contractors achieved 23 million safe work hours without a lost-time incident. The Saudi Kayan Project in total achieved 51 million safe work hours.

Conclusion

We successfully delivered the water systems on the Saudi Kayan Petrochemical project, including water treatment, wastewater treatment, seawater cooling tower and potable water.

The Saudi Kayan project received Fluor's Hugh Coble Project Excellence Award, based on outstanding performance in several areas, including safety, value creation and client and community relations.