The Fadhili gas plant is a greenfield development to be constructed 30km west of Jubail in Saudi Arabia’s eastern province. The facility is being built by Saudi Aramco with an estimated investment of SAR50bn ($13.3bn).
The gas plant is a notable part of Saudi Arabia’s proposed Master Gas System that has been planned to fulfil the increasing energy demand in the country by expanding the kingdom’s sales gas capacity from 9.3bcf/d in 2015 to 12.2bcf/d in 2021. An estimated addition of 5bcf/d is expected to occur in the country’s non-associated gas processing capacity with the completion of the Wasit, Midyan and Fadhili gas plants.
A signing ceremony for the project was held on 20 July 2016 to signal the start of the mega project. Scheduled to be completed by the end of 2019, the project will supply energy through the clean-burning of natural gas and help lower the country’s reliance on oil as a fuel for generating power.
The plant is expected to generate 4,500 employment opportunities, including both permanent and temporary jobs, benefitting the locals. A training centre will be set up in collaboration with project contractors and government agencies to impart a Fadhili training programme to develop technical skills.
Details of Fadhili gas plant
With a processing capacity of 2.5bcf/d, the Fadhili gas plant will process gas from both onshore and offshore fields. It will process an estimated 2bcf/d of non-associated gas from Hasbah offshore gas field and 500mmcf/d of gas from Khursaniyah onshore gas field.
The gas plant will produce 1.5bcf/d of sales gas and 4,000 metric ton a day of sulphur. It will additionally yield 470mmcf/d of gas that will be supplied to a co-generation power plant located nearby and being constructed as part of the gas project.
Construction of the gas plant is divided into three parts, namely gas processing unit, utilities and offsite facilities such as nitrogen, steam, power and water systems, and sulphur recovery.
The plant will comprise five processing trains of which four trains will process gas from the offshore Hasbah gas field and will include facilities for inlet gas handling, gas sweetening and dehydration. Gas from the onshore Khursaniyah gas field will be processed by one train that will comprise inlet gas handling, and gas sweetening.
The gas processing trains will be equipped with power recovery hydraulic turbine technology instead of conventional control valves to record pressure drops with greater accuracy.
Gas from the offshore field will be directly supplied to the adjacent co-generation plant after being processed in the treatment system, which has been optimised accordingly. The gas plant will have maximum sulphur recovery of 99.9% due to the adoption of tail gas treatment process.
The operator plans on adding a helium recovery plant and a CO2 recovery unit for checking emissions in the future as part of the Fadhili gas plant.
Co-generation plant details
A co-generation power plant will be constructed by a joint venture of Saudi Aramco (60%) and Saudi Electricity Company (60%). The project is being developed as per a build, own, operate and transfer system (BOOT) agreement that is valid for a period of 20 years.
The co-generation plant will have a capacity of 1,500MW including 400MW for the gas plant, while the remaining 1,100MW will be supplied to the national grid.
Key players involved
Tecnicas Reunidas was awarded two turnkey contracts including detailed engineering, procurement and supply of equipment and materials. It will also provide services for construction of the plant and assistance during the commissioning. The two contracts are related to the Fadhili gas inlet and treatment facilities, utilities and interconnecting systems.
Petrofac has been selected to perform engineering, procurement and construction (EPC) of the sulphur recovery plant. The scope of work includes construction of six sulphur recovery trains and associated facilities for the sulphur and heavy-duty oil handling, loading, unloading and storage, sour water stripper, flare system and wastewater treatment plant.
Foster Wheeler was contracted for providing engineering and project management services, as well as the execution of the FEED. Cost estimates, procurement of long-lead equipment and basic engineering design will also be performed by Foster Wheeler.
Contract for the co-generation plant was awarded to Saudi Electric Company and Engie, while a contract for downstream pipelines was awarded to Saudi KAD. A residential building at the project location will be constructed by Mohammed I. Al Subeae & Sons Investment Holding Company (MASIC).
AlKifah ready-mix and blocks was selected to supply building material for the construction of the project. A contract for design and implementation of communications and security systems has been awarded to Wipro.
A consortium of L&T Hydrocarbon Engineering and EMAS CHIYODA Subsea was given a $1.6bn EPCI contract for performing work on the Hasbah gas field. The companies will be responsible for providing pipelines for transporting gas from the field to the gas plant.