Jurong Rock Caverns

Development of Underground Rock

Caverns for Storage of Liquid
Hydrocarbons on Jurong Island
Er. Teo Tiong Yong

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
 Stakeholders
Developer Main Contractors
JTC Corporation Sato Kogyo (Access Shafts)
Hyundai Engineering & Construction
Project Management Team (Tunnels & Caverns)
Sintef-Tritech-Multiconsult Consortium

BED / Superintending Officer Consultants

Geostock (Access Shafts) Kiso-Jiban Consultants
Geostock-Jurong Consultants Parsons Brinckerhoff Singapore
Consortium (Tunnels & Caverns) K L Au Consultants
Beca Singapore

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
JRC is located below the seabed at Banyan Basin,
Jurong Island

Jurong
Island

Banyan
Phase 1 Basin
JRC
Aboveground Banyan
Facility Basin

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
 Development of
Jurong Rock Caverns
 Underground Rock Caverns for Oil
Storage
Aboveground land used for production; underground land used for storage

Storage in 60 Ha of surface
aboveground land freed up
tanks

• Creating a competitive advantage

• Saving surface land

• Improved security Storage in

underground
• Improved health & safety rock caverns
Singapore – 11 November 2016
 Jurong Rock Caverns Journey

2009: Started construction of

main caverns
2Q 2014: Completion of 1st two
2007: Started construction of caverns to serve JAC
access shafts

Construction of
Feasibility & Business Studies, Engineering Design Access Shafts
Construction of Main
Soil Investigation and Funding of Access Shafts & Engineering
Caverns
Approval Design of
Main Caverns

2001 2006 2007 2009 2Q2014 2017

2006: Funding approval obtained for 1Q 2017: Completion of

Phase 1 development Jurong Rock Caverns

Site Investigation Access Shaft Construction Tunnel Excavation Completed Cavern

6
Singapore – 11 November 2016
 Overall Development of JRC

3.2 ha
JURONG ISLAND
Access Shaft 3

Phase 1 & 2 =
30 Ha

Access Shaft 1 Phase 1

Cavern Storage
Caverns Notation Product
Volume (m3)

Cavern 1 Crude Oil, 1 x 150,000

Multi-purpose Condensate
Product Jetty Caverns 2 to 5 4 x 330,000
Total Storage Volume (m3) 1,470,000

*Condensate is a hydrocarbon liquid for production of aromatics

which in turn is used to make fabric and plastic. 7
Singapore – 11 November 2016
Layout Plan of Phase 1

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
 Cross Section of Shafts, Tunnels &
Caverns

Banyan Basin Access Shaft 3

Access Shaft 1
Maintenance
Chamber Operation Tunnels

Access Tunnels 132m

Oil Storage Cavern
Oil, Seepage belowground
Water Pump
Sump

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
Typical Cross Section of a Cavern Gallery

• 9 storeys high (27 m)

• Length = 340 m

• Excavation using drill and blast

method with grouting (if

27m
required)

• Volume per storage cavern =

165,000m3
(two typical storage tanks of
80,000m3 capacity)
20m

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
Technical Innovation:
How Does the Underground Oil Storage
Work?

• Our Caverns are unlined

• Caverns roofs are below

groundwater table

• Water pressure keeps oil

within the caverns

• Water that seeps in is

collected and pumped up
automatically

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
 Underground
10m Expressways,
20m Underpasses &
Shopping Malls
30m
MRT System
40m Singapore
Power Cable
How deep 50m
Tunnel
is Jurong 60m
Deep Tunnel
Sewerage System
Rock 70m

80m
Caverns?
90m

100m

110m

120m

130m
Jurong
140m Rock
150m Caverns
Singapore – 11 November 2016
 Construction of Access Shafts, Tunnels and Caverns
Access
Shaft 3

Access
Shaft 1

Access Shafts Contractor: Sato Kogyo

Caverns Contractor: Hyundai Engineering and Construction

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
 Construction of Access Shafts 23.9m

BLOWS/30CM
BLOWS/30CM
21.5m
Diaphragm Wall
N-VALUE
N-VALUE
DEPTH
DEPTH

FI
&FI
RQD
TCR

RQD
SCR
TCR

SCR

WG&
EXTG. Ground
Ground Level
Level RL103.300
RL103.300 = RL103.259 = ACD +5.0m CAPPING BEAM
WG
ACD +5.041m

with Ring Beams

m % % %

-1.5 RECLAIMED

4.7m
4.7m
-3.0 12
12 SAND
Reclaimed
13
Sand Section D 400mm Skin Wall
-6.0
by others

4m
4m
6 FINE TO
-9.0
COARSE SAND DIAPHGRAM WALL RC RING BEAM
Fine to Coarse

4m
-12.0
9 t=1.0m 1.0mx1.0m
Sand

28m
22

4m
-15.0
CLAYEY
-18.0
41
Clayey Silt SILT

3.72m 4m
(JURONG
46
-21.0(Residual Jurong
FORMATION)
RC RING BEAM
100/ 1.0mx1.5m
-24.4 26 Formation)
III
62 18 4 IV
ACD-21m CL 11 CL 11
-27.0 CL CL

2m
>16
III ACD-23m CL
CL 22 CL 22
CL

-27.7 100 96 43 10 CL 33
CL CL 33
CL

Concrete Lining
III CL
CL 44 CL 44
CL

60 18 18 IV CL
CL 5
5 CL 55
CL

-30.7 10 CL
CL 66 CL 66
CL

CL
CL 77 CL 77
III CL

CL
CL 8 CL 88
4 V
8 CL
50 9 CL
CL 99 CL 99
-33.7 >16 Section E CL
CL

CL 10
10 CL 10
CL 10
II
CL 11
CL 11 CL 11
CL 11
100 45 15 III CL
CL 12 CL 12
12
-36.4 13
II
CL
12

CL 13
13
CL

CL 13
CL 13
III
-37.6 100 54 18 12 CL
CL 14
14 CL 14
CL 14

-39.5
Siltstone and
68 39 15 >16
II
III
CL 15
CL

CL
15

CL 16
16
CL 15
CL 15

CL 16
CL 16

CL
CL 17
17 CL 17
CL 17
II
Sandstone 48 25 6 III CL 18
18 CL 18
18

32m
CL CL

-42.4 >16 CL
CL 19
19 CL 19
CL 19

CL
CL 20
20 CL 20
CL 20
II

-45.4
(Jurong 43 19 0 III
>16
CL 21
CL

CL
21

CL 22
22
CL 21
CL 21

CL 22
CL 22

CL
CL 23
23 CL 23
CL 23
II

-48.4
Formation)28 6 0 III
>16
CL
CL 24
24

CL 25
CL 25
20.55m
CL 24
CL 24

CL 25
CL 25

CL
CL 26 CL 26
26
II 26 CL

-50.0 44 13 0 >16 ACD-48m CL

CL 27
27 CL 27
CL 27

CL
CL 28 CL 28
28
I 28 CL

100 87 77 II CL 29
CL 29 CL 29
CL 29

-53.0 I5I CL
CL 30
30 CL 30
CL 30

III CL 31
CL 31 CL 31
CL 31

-54.3 100 69 52 10 CL 32
CL 32 CL 32
CL 32

II III CL 33
CL 33 CL 33
CL 33

-56.0 100 74 54 11
ACD-55m CL
CL 34
34
CL 35
CL 35 CL 35
CL 35
CL 34
CL 34

I
-57.5 100 95 93 5

-60.5 100 100 93 2I SILTSTONE

AND

131m
I
-63.5 100 100 100 <1 SANDSTONE
10.7m 10.7m

Shotcrete and
(JURONG
-66.5 100 95 85 III FORMATION)
I
-69.5 100 100 100 <1
I
18.3m
-72.5 100 100 100 0

Rock Bolts
I
100 100 100 <1
-75.5
I
100 97 78 4I
-78.5
I
-81.0 100 96 86 5

-83.0
Siltstone
100 100 100 and I
1
I
-84.5 Sandstone
100 87 60 8
I
-86.5 100 96 96
100(Jurong
4

-89.0 100 100

I
0
34.4m
I
-90.5 Formation)
100 100 100 0 ACD -86.000 m ACD -86.300 m
I
-93.5 100 100 100 1to2
I
100 100 98 <1
-96.5
100 88 88
I
2
ACD -93.525 m
-99.5
-102.5 100 100 95 I
I
-104.0 100 100 100 0
I
-105.5 100 100 100 <1

9400

Section F

ACD -126.025m

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
Typical Cross Section
 Construction of Tunnels and Caverns
using Drill and Blast Method

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
Construction Challenges: Limitations in the
Sequencing of Underground Works

Use of T-Lift for mucking out and

vehicle movement

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
Construction Challenges: Limitations in the
Sequencing of Underground Works

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
Technical Challenges: Geological &
Hydrogeological Risks

Singapore – 11 November 2016

Technical Challenges:
Geological & Hydrogeological Risks
• Venturing so deep underground in sedimentary rock is breaking new
ground
• Unpredictable geological conditions
• Adopting systematic deep investigation boreholes and probe holes.
• Pre-grouting to reduce groundwater seepage
• Continual probing and site investigation before excavation
• Pre-grouting to reduce groundwater seepage
• Adapt excavation methods to site conditions

Singapore – 11 November 2016

Technical Innovation:
Use of Explosives

• Explosives Storage Houses (ESH) were constructed to

have 24hours/7days access to explosives for excavation
works to improve construction productivity

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
Movement of Products

Pipelines connecting JAC and JRC

Singapore – 11 November 2016
Pipelines to Very Large Crude Carrier Jetty
Overview of Aboveground Facilities

Wastewater
Treatment Plant
Vapour
Recovery Unit
Valve Manifold Area

Export Booster Pipe Rack

Pump & Metering & Pipes
Area Jetty

Administration
Building

Pipe Rack
& Pipes

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
Status of JRC Project

Caverns 1 and 2
• Construction of caverns completed in Aug 2013
• Construction of supporting facilities completed in Mar 2014
• Testing and commissioning from Apr 2014
• Started operations for Jurong Aromatics Corporation on 1 Jul 2014

Caverns 3, 4 and 5
• Construction of caverns completed in Jun 2014
• Construction of supporting facilities completed in early 2016
• Testing & Commissioning currently on-going

Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong
 SPMI – Project of the Year ASEAN Outstanding
Award 2015 - 2016 Engineering Achievement
(Engineering & Construction) Awards 2015

IES Prestigious
SG Mark Engineering Awards 2015
Platinum 2015
TOP 50 Engineering
Feats @ IES-SG50 (2016)

Singapore Structural Awards 2014

Commendation Award for Industrial Structures

Thank You
Singapore – 11 November 2016 Jurong Rock Caverns – Er. Teo Tiong Yong