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Experience

Sadara Project

The world’s largest chemical complex ever built in a single phase


Client:
Sadara Chemical Company (Saudi Aramco and Dow Chemical Company joint venture)

Location:
Al-Jubail, Kingdom of Saudi Arabia

Scope:

Engineering, Construction, Consulting, Program Management

Year:

2007

Project Details

  • The Sadara Chemical Project is the world’s largest chemical complex ever built in a single phase. With 26 integrated world-scale manufacturing plants that will produce more than 3 million tons of high-value-added chemical products every year, we anticipate that Sadara Chemical Company will become a Fortune 500 company within the first year of full operation.
  • KBR performed pre-FEED activities for the entire Sadara project. During pre-FEED KBR supported the optimization of the process units, preliminary plant layout, integration with third-party providers (feedstock, utilities, infrastructure), and early cost analysis. The pre-FEED work resulted in a significantly different product slate for the project and the relocation of the site to Jubail to mitigate the costs and risks associated with the original site.
  • KBR was the FEED contractor for the Aromatics unit; the Ethylene Oxide and Derivative units (Chem III); Propylene Oxide and its Derivative units (Chem III); Isocyanate (Chem III – PMDI and TDI) units and Leveraged Assets. KBR’s FEED packages were provided to third-party EPC bidders, and KBR continued support during the engineering and procurement phase in the EPC contractor offices to facilitate knowledge transfer and clarify questions as they arose.
  • KBR provided industry-leading subject-matter experts to the Sadara project management team (PMT) in numerous areas, including:
    • Scheduling and planning
    • Cost estimating
    • Procurement
    • Information management
    • Engineering design in civil, tanks, machinery, pressure vessel, process automation, piping, electrical power systems, environmental permitting and more
  • KBR was part of an integrated PMT (IPMT), coordinating project management consultant (CPMC) along with the Sadara client, and peaked at over 500 specialized personnel in countries outside Saudi Arabia and nearly 700 at the Jubail site.
  • KBR developed the conceptual design and managed the reporting activities during execution to the export credit agency (ECA) financing for the program. Sadara obtained approximately $7 billion through ECA financing. The largest came from the U.S. Export-Import Bank, known as “EXIM”, and was in the amount of $4.9 billion, the largest in its history.
  • KBR intends to continue its long-standing partnership with Sadara throughout the commissioning, operations and maintenance phases of the project.
  • KBR’s in-kingdom entity exceeded the Saudi Ministry of Labor (MOL) Saudization metrics (Nitaqat System) and is currently classified in the highest “Platinum” ranking, allowing favorable treatment by the MOL in issuing and dealing with work visas.

Project Highlights

  • In August 2015, the Sadara Chemical Project achieved 80 million construction man-hours without a lost-time incident (LTI).
  • The project achieved an impressive overall OSHA total recordable incident rate (TRIR) of 0.033, with over 500 million construction hours.
  • KBR expended nearly 8.5 million man-hours on this project, and is proud of the world-class safety statistics achieved with an OSHA TRIR of 0.024 and zero incidents since 2009.
  • KBR’s culture of Zero Harm requires a full commitment by every employee throughout the organization. The KBR on-site team performed hundreds of joint safety walk-throughs with the project management team (PMT) and their construction contractors.
  • KBR provided the Sadara site induction training, as well as specialized training for PMTs and contractors, to more than 275,000 people. The objective of the training was to ensure familiarity with the appropriate HSSE programs covering a range of safety values, including hazard recognition and mitigation.
  • Safety was further reinforced through safety observations and by empowering employees to recognize and intervene in at-risk behaviors or conditions requiring improvement.
  • This provided opportunities for employee development and coaching in a learning environment.
  • The Sadara Chemical Joint Venture won the 2015 top petrochemical project award from Hydrocarbon Processing readers through an online survey and was selected for its impact on the global petrochemical industry.
  • Along with Sadara, KBR was awarded the U.S. Export Import bank (EXIM) “Deal of the Year” award in 2013.
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