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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:

Program Management, Pre-FEED, FEED

Year:

2017

Project Details

  • The Sadara Chemical Project, a joint-venture of Saudi Aramco and Dow, 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.  The project was successfully completed in 2017 is delivering products since then..
  • Saudi Aramco and Dow partnered with KBR early in the development of the project configuration to establish a strong foundation for project delivery success.  KBR performed the role of Program Management Contractor starting from the pre-feasibility phase and assisted the Owner team refine and finalize an optimized project configuration at a more viable project site near Jubail.
  • KBR’s Project Management team was part of an integrated PMT (IPMT) and undertook the role of the Coordinating PMC (CPMC) overseeing performance of services by several other PMCs engaged to deliver specific sections of the Giga Complex along with the Samara client. As a CPMC, KBR provided resources and peaked at over 500 specialized personnel in countries outside Saudi Arabia and nearly 700 at the Jubail site.
  • As the CPMC, KBR developed the project standards and specifications, quality assurance programs, communications and interface protocols, established the project leveraged procurement agreements with global suppliers, conducted logistics studies and prepared and implemented project procedures, tools, and systems for use by the entire contracting community of over 40 EPC contractors who were engaged in project completion through the EPC phase. The entire project was digitally delivered.
  • As a part of the CPMC, KBR supported owner implement the world’s largest Leveraged Assets Project comprising an integrated infrastructure of Management Information Systems, Manufacturing Operations Management Systems, Plant Automation Systems, Laboratory Management Information Systems, and the Analyzer Data Management system. 
  • KBR’s CPMC team also supported the Owner team with development of Operating Procedures, training of several thousand operators, and delivery procedures, and its embedded resources helped Owner team complete each project through start-up.
  • 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 also provided the key role of coordinator of financing activities by interfacing with several major national Export Credit Agencies (ECAs) that provided financing to 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.
  • 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 intends to continue its long-standing partnership with Sadara throughout the commissioning, operations and maintenance phases of the project.
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