A-1 - Introduction To Shuqaiq IWPP

SAUDI ARABIA
SHUQAIQ-2 IWPP PROJECT

COURSE-A
ITEM - General
CONTENTS
A-1. Introduction to Shuqaiq-2 IWPP Project

06 June 2009
MITSUBISHI HEAVY INDUSTRIES, LTD.

NAGASAKI SHIPYARD & MACHINARY WORKS
GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project
PAGE 2
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Salient Features of Project

MHIs Past Experiences in K.S.A
Overall Plan
Project Outline
Project Location
Project Organization
Plant Layout
Plant Summary
Design Concept
Major Equipment
Overall Project Schedule
MHI BUSINESS
CONFIDENTIAL
PAGE 3
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Overall Plan
Project Outline
Project Location
Plant Layout
Plant Summary
Design Concept
Major Equipment
MHI BUSINESS
CONFIDENTIAL
PAGE 4
1. Salient Features of Project

1.
Plant to be Lump Sum Turnkey Contract for 850 MW net power generation
& 212,000 m3/day RO plant
2.
Major equipment Sourced from Quality Assured Overseas Suppliers

including Japan
3.
Structural Steel along with several equipment Sourced from Qualified Domestic Local Suppliers.
4.
Plant Availability Ensured through selection of Quality Products, Choice of

Reputed Vendors and provision of Adequate Margin over
Duty Points
MHI BUSINESS
CONFIDENTIAL
PAGE 5
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Overall Plan
Project Outline
Project Location
Plant Layout
Plant Summary
Design Concept
Major Equipment
MHI BUSINESS
CONFIDENTIAL
PAGE 6
2. MHIs Past Experiences in K.S.A
MHI BUSINESS
CONFIDENTIAL
PAGE 7
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Overall Plan
Project Outline
Project Location
Plant Layout
Plant Summary
Design Concept
Major Equipment
MHI BUSINESS
CONFIDENTIAL
PAGE 8
3. Overall Plan Shuqaiq-2 IWPP Project (850 MW)

Air
Water
Arabian Heavy Crude Oil

Phase 2
Unit 1
Unit 2
Unit 3
340 MW
340 MW
340 MW
Flue Gas
Flue Gas
Flue Gas
(212,000m3/day)
Waste Water
Waste Water
Waste Water
Waste Water
RO Plant
Potable Water
MHI BUSINESS
CONFIDENTIAL
PAGE 9
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Overall Plan
Project Outline
Project Location
Plant Layout
Plant Summary
Design Concept
Major Equipment
MHI BUSINESS
CONFIDENTIAL
PAGE 10
4. Project Outline
1) Project Name
Shuqaiq-2 Independent Water and Power Plant (IWPP) Project
2) Scope of Supply
Lump Sum Turnkey Contract for
- 850 MW Net Power Generation
- 212,000 m3/day RO Plant
MHI BUSINESS
CONFIDENTIAL
PAGE 11
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Overall Plan
Project Outline
Project Location
Plant Layout
Plant Summary
Design Concept
Major Equipment
MHI BUSINESS
CONFIDENTIAL
PAGE 12
5. Project Location - 1 of 3
Project Location:
Shuqaiq-2 IWPP Project is located next to existing
SWCC Shuqaiq Phase-1 Project
1) 600 km apart from Jeddah city

2) About 100 km distance from Abha, south-west direction
3) About 140 km distance from Jizan, north direction on the
shore of Red sea.
MHI BUSINESS
CONFIDENTIAL
PAGE 13
Plant Location From Global Image
Shuqaiq-2 IWPP
MHI BUSINESS
CONFIDENTIAL
PAGE 14
Plant Location From Local Image
Sh S
uq qW
aiq EC
-2 /
IW
PP
MHI BUSINESS
CONFIDENTIAL
PAGE 15
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Overall Plan
Project Outline
Project Location
Plant Layout
Plant Summary
Design Concept
Major Equipment
MHI BUSINESS
CONFIDENTIAL
PAGE 16
6. Project Organization - 1 of 4
=> Major Parties Involved in the Contract:
- Owner
SHUQAIQ Water & Electricity Company, K.S.A.
-Owners Engineers ( Consultant )
ILF Consulting Engineers, Germany
- Contractor
Mitsubishi Heavy Industries Ltd. (MHI), Japan
MHI BUSINESS
CONFIDENTIAL
PAGE 17
6. Project Organization (Overall) - 2 of 4
MHIs Sub-Contractors
ARCC
MHI BUSINESS
CONFIDENTIAL
PAGE 18
6. Project Organization (MHI Nagasaki) - 3 of 4
Overall Training
Organizer
Classroom Training
Conductor
MHI BUSINESS
CONFIDENTIAL
PAGE 19
6. Project Organization (MHI Shuqaiq Site) - 4 of 4
OJT Conductor
MHI BUSINESS
CONFIDENTIAL
PAGE 20
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Overall Plan
Project Outline
Project Location
Plant Layout
Plant Summary
Design Concept
Major Equipment
MHI BUSINESS
CONFIDENTIAL
PAGE 21
7. Plant Layout - 1 of 2
Jeddah
Access Road
Ro
ad
132 Kv
&
Ac
ce
s
13
Jizan H
ighway
&
v
K
0
38
or
c
v
er
d
ri
380 Kv
corride
r
See next sheet !

Plant Main Entrance
MHI BUSINESS
CONFIDENTIAL
PAGE 22
7. Plant Layout - 2 of 2
Overview from South-East

See next motion view !
MHI BUSINESS
CONFIDENTIAL
PAGE 23
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Overall Plan
Project Outline
Project Location
Plant Layout
Plant Summary
Design Concept
Major Equipment
MHI BUSINESS
CONFIDENTIAL
PAGE 24
8. Plant Summary - 1 of 2
Plant Configuration
Arabian Heavy Crude Oil Fired, Conventional

Type with RO Desalination
Main Fuel
Arabian Heavy Crude Oil
No. of Units
Power Units - 3 nos.

RO Unit -1 no, 16 trains
Each power unit consists of
Boiler 1 no.
Turbine 1no.
FGD 1 no.
Power Unit
Common Units
Sea Water supply

Fuel oil supply
Ash Handling system
Demin. Plant
Waster Water system
MHI BUSINESS
CONFIDENTIAL
PAGE 25
8. Plant Summary - 2 of 2
Main Performance Data: Site conditions : RSC, Load MCR
Net Heat rate for the plant
10,394 kJ/kWh
Gross heat rate for each power unit
8,662 KJ/KWh
Total net power output (net from three units)
850MW
Gross power output per unit
340 MW
Net Power output per unit
283.33 MW
Maximum continuous rating (Steam)
1,080 ton/h
Total auxiliary power consumption
170 MW (not guaranteed)
Net water output
212,000 m3/day
Gross water output
216,000 m3/day
1,000 m3/day
Waste water treatment system
MHI BUSINESS
CONFIDENTIAL
PAGE 26
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Overall Plan
Project Outline
Project Location
Plant Layout
Plant Summary
Design Concept
Major Equipment
MHI BUSINESS
CONFIDENTIAL
PAGE 27
9. Design Concept
1. Compliance with Environmental Requirement
2. Enhanced Reliability and Availability with proven MHIs
equipment
3. Enhanced Thermal Efficiency
Steam Turbine: 3-D profile and Integral Shroud Blades
4. Easy Operation
Mitsubishi DCS specifically customized for Boiler and
Turbine, and PLC control customized for FGD, EP, and
Water treatment as manufacturers standard
MHI BUSINESS
CONFIDENTIAL
PAGE 28
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Overall Plan
Project Outline
Project Location
Plant Layout
Plant Summary
Design Concept
Major Equipment
MHI BUSINESS
CONFIDENTIAL
PAGE 29
10. Major Equipment - Boiler 1 of 2

MANUFACTURER
MHI-Nagasaki
DESIGN
CONDITION
100% B-MCR
QUANTITY
3 nos.
TYPE
Water Tube Boiler

- Outdoor
- Single-Drum
- Forced Circulation
- Forced Draft System
EVAPORATION
1080 t/h (B-MCR)
MAIN & REHEAT

STEAM
CONDITIONS
172.6 barg x 541 @SH

41 barg x 541 @RH
LOW NOx
COMBUSTION
SYSTEM
Circular corner firing,

OFA system
MHI BUSINESS
CONFIDENTIAL
PAGE 30
10. Major Equipment - Boiler 2 of 2

BOILER FRONT
REAR WALL UPPER
HEADER
ECONOMIZER OUTLET
HEADER
1RY SH INLET PIPE
1RY SH OUTLET
HEADER
ROOF INLET HEADER
FRONT WALL UPPER
HEADER
SIDE WALL
OUTLET HEADER
2RY PASS SIDEWALL

OUTLET HEADER
WIND BOX
ROOF PANEL
STEAM DRUM
REAR WALL SCREEN TUBES
R
NE
BOILER
CIRCULATION
PUMP
ECO
GAS TEMPERATURE
PROBE
R
NE
(T)
ER
RN
BU
CL
R
BU
CL
EXPANSION JOINT
NONMETALLIC
1RY SH
C
L OF BOILER
GAS RECIRCULATION FAN
CL
FLUE GAS
TO EP
C
L
AIR HEATER 1B
AIR DUCT
STEAM DRUM
C
LFURNACE
OBSERVATION
PORT
C
L OF BOILER
2RY SH
DESUPERHEATERS
FRONT WALL
HANGER TUBE
E
RN
BU
CL
SECTION A-A
1RY RH
C
L
AIR HEATER 1A
SECTION B-B
3RY SH
R
BU
CL
ACCESS DOOR
C
L FURNACE
2RY PASS REAR WALL TUBES

SOOT BLOWER
2RY RH
DOWN COMER
C
LOFA
C
LOFA
C
L BURNERS
BCP INLET
MANIFOLD
STEAM AIR HEATER

SILENCER
C
L BURNERS
CLFORCED DRAFT FAN
C
L
AIR HEATERS
C
L BURNERS
SILENCER
C
L BURNERS
SILENCERS
BOILER
CIRCULATION
PUMPS
EXPANSION JOINT
+0
BCP OUTLET
MANIFOLD
FORCED DRAFT FANS 1A,1B
FURNACE LOWER HEADER

FURNACE LOWER HEADER
INLET PIPE
GAS RECIRCULATION FANS 1A, 1B
EXPANSION JOINT
NON-METALLIC
MSD-3-0019
Boiler General Arrangement

MHI BUSINESS
CONFIDENTIAL
PAGE 31
10. Major Equipment - Steam Turbine 1 of 2

MANUFACTURER
MHI-Nagasaki
DESIGN
CONDITION
100% T-MCR
QUANTITY
3 nos.
TYPE
Two Cylinders, Tandem

Compound, Double Exhaust,
Condensing, Reheat Type
RATED OUTPUT
340 MW
DESIGN STEAM
CONDITIONS
166.7 bar(a) x 538 @MSV In.

38.8 bar(a) x 538 @RSV In.
RATED SPEED
3600 rpm
No. OF
EXTRACTIONS
Seven
GOVERNOR
SYSTEM
Electro-Hydraulic System
MHI BUSINESS
CONFIDENTIAL
PAGE 32
CL OF NO.2 BRG.
C
L OF MAIN OIL PUMP
C
L OF NO.1 BRG.
C
L OF NO.4 BRG.
NO.2&3 BEARING
PEDESTAL
C
L OF THRUST BRG.
GOV. SIDE
CL OF MAIN STEAM INLET
GEN. SIDE
CL OF NO.3 BRG.
CL OF LP. TURBINE
10. Major Equipment - Steam Turbine 2 of 2
MAIN STEAM INLET
VIBRATION
PICKUP
SPEED PICKUP
VIBRATION
PICKUP
DIFFERENTIAL
PICKUP
NO.4 BEARING PEDESTAL
VIBRATION
PICKUP
KEY PHASOR
PICKUP
ECCENTRICITY
PICKUP
VIBRATION
PICKUP
ROTOR POSITION
PICKUP
ROTOR GROUNDING
DEVICE
ROTATION
C
L OF T/G UNIT
NO.1 EXTRACTION
NO.2 EXTRACTION
NO.2 EXTRACTION
NO.3 EXTRACTION
NO.4 EXTRACTION
LP TURBINE
GLAND STEAM OUTLET
NO.1 EXTRACTION
GLAND STEAM INLET
GLAND STEAM INLET
OPERATING FLOOR
GLAND STEAM OUTET
OPERATING FLOOR
NO.5 EXTRACTION
REHEAT STEAM INLET
NO.6 EXTRACTION
HP EXHAUST(NO.7 EXTRACTION)
MAIN STEAM INLET
HP-IP TURBINE
MSD-3-0071
Sectional View of Turbine Assembly

MHI BUSINESS
CONFIDENTIAL
PAGE 33
10. Major Equipment - Generator

MANUFACTURER
Mitsubishi Electric Co.
DESIGN
CONDITION
Maximum Output
QUANTITY
3 nos.
TYPE
Horizontal mounted cylindrical

rotor, Rotating field type,
Hydrogen indirect cooled stator ,
Hydrogen direct cooled rotor
MVA OUTPUT
448 MVA
MW OUTPUT
358.4 MW
VOLTAGE
21 kV
CURRENT
12.317 kA
SPEED
3600 rpm
FREQUENCY
60 Hz
Unit 1 Generator Rotor Under Fabrication
Unit1 Generator Stator Frame Under

Fabrication
MHI BUSINESS
CONFIDENTIAL
PAGE 34
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Overall Plan
Project Outline
Project Location
Plant Layout
Plant Summary
Design Concept
Major Equipment
MHI BUSINESS
CONFIDENTIAL
PAGE 35
11. Overall Project Schedule - 1 of 8

1) Signed Date of Contract Agreement : 28 February 2007
MHI BUSINESS
CONFIDENTIAL
PAGE 36

2) Notice to Proceed
: 31 May 2007
MHI BUSINESS
CONFIDENTIAL
PAGE 37

2) Notice to Proceed
: 31 May 2007
Provisional Acceptance Certificate

1. Power Unit 1 PAC
: 30 April 2010
2. Power Unit 2 PAC
: 15 August 2010
3. Power Unit 3 PAC
: 10 November 2010
4. RO Unit PAC
: 05 May 2010
All Units Completion : 30 November 2010

MHI BUSINESS
CONFIDENTIAL
PAGE 38

Signed
NTP
28 Feb 07
31 May 07
RUNNING MONTH
DESCRIPTION
1
U1-Drum
Lifting
15Jan 09
2007
2007
1 2 3 4 5 6 7 8
-5 -4 -3 -2 -1 1 2 3
U1-Hyd
Test
U1-Init.
Firing
15 Jun 09
15 Nov 09
2008
9 10 11 12 1
4 5 6 7 8
U1 Synch
15 Jan 10
2009
2010
2008
2009
2010
2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
KEY SCHEDULE (TARGET)

No.1 BOILER UNIT
No.1 TURBINE UNIT
UNIT-1
C
UNIT-2
UNIT-3
S
ALL
ERECTION WORK START
DESALINATION PLANT (RO)
E
SELECTION OF
SHORTLISTED BIDDERS
PWPA
COMPLETION OF POWER
TRANSMISSION FACILITIES
CLOSING DATE
PROJECT SCHEDULE
- TRANSMISSION LINE (TP1*, TP2*, TP3*)
- LOAD DISPATCH CENTER
- FUEL OIL SUPPLY
- CONNECTION OF NEW POTABLE WATER (TP4*)
* TP: Terminal Point in MHI Plot Plan (H20-001, 1/2)
COMPLETION OF WATER
TRANSMISSION FACILITIES
ICOD
PCOD
for Synchronize
Power Receiving at
Substation
Light
Crude
U1- Compl
U2 Comp.
U3 Compl.
30 Aprl 10
15 Aug 10
10 Nov10
RO Comp.
05 May 10
Microsoft Excel
MHI BUSINESS
CONFIDENTIAL
PAGE 39
Pile Load Test
Bored Pile
MHI BUSINESS
CONFIDENTIAL
PAGE 40
#1 Boiler Drum Lifting
MHI BUSINESS
CONFIDENTIAL
PAGE 41

Boiler Unit 1
Turbine Building
Unit 1
CCB
MHI BUSINESS
CONFIDENTIAL
PAGE 42

Turbine Building-unit 1
Fl- +12000
MHI BUSINESS
CONFIDENTIAL
PAGE 43
A-1. Introduction to Shuqaiq-2 IWPP Project
End
MHI BUSINESS
CONFIDENTIAL

A-1 - Introduction To Shuqaiq IWPP

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SAUDI ARABIA

SHUQAIQ-2 IWPP PROJECT

A-1. Introduction to Shuqaiq-2 IWPP Project

MITSUBISHI HEAVY INDUSTRIES, LTD.

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

Salient Features of Project

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

Salient Features of Project

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

1. Salient Features of Project

Major equipment Sourced from Quality Assured Overseas Suppliers

Plant Availability Ensured through selection of Quality Products, Choice of

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

Salient Features of Project

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

2. MHIs Past Experiences in K.S.A

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

Salient Features of Project

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

3. Overall Plan Shuqaiq-2 IWPP Project (850 MW)

Arabian Heavy Crude Oil

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

Salient Features of Project

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

Salient Features of Project

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

1) 600 km apart from Jeddah city

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

Salient Features of Project

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

6. Project Organization (Overall) - 2 of 4

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

6. Project Organization (MHI Nagasaki) - 3 of 4

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

6. Project Organization (MHI Shuqaiq Site) - 4 of 4

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

Salient Features of Project

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

See next sheet !

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

Overview from South-East

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

Salient Features of Project

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

Arabian Heavy Crude Oil Fired, Conventional

Arabian Heavy Crude Oil

Power Units - 3 nos.

Sea Water supply

GeneralGeneral-Introduction to ShuqaiqShuqaiq-2 IWPP Project

Gross heat rate for each power unit

Total net power output (net from three units)

Gross power output per unit

Net Power output per unit

Maximum continuous rating (Steam)

Total auxiliary power consumption

170 MW (not guaranteed)

Net water output

Gross water output

Waste water treatment system