Al Zour Refinery

The Al Zour Refinery is the second largest refinery in the Middle East.

This scheme comprised the provision of specialist marine consultancy services on a new, grassroots, 615,000 barrels per day oil refinery project in Kuwait. When completed, the billion-dollar Al Zour Refinery will increase Kuwait’s refinery capacity by 615,000. It will be a key part of Kuwait’s long term strategy, producing cleaner fuels to meet its electrical power generation growth and demand, while adhering to the latest environmental standards.

The project included construction of a new small boat harbour with 600 metres of quay wall, solids export berth 3 kilometres offshore connected to the shore by piled approach trestle, 6 million cubic metres of reclamation for a new LNGI (Liquefied Natural Gas Import Facility) terminal, steel pile sea island located 17 kilometres offshore, supplied by five 17 kilometres long subsea pipelines.

The project phases are as follows:

• Phase 1 – Preliminary design
• Phase 2 – Pre-EPC contract award phase
• Phase 3 – EPC contract detailed engineering and procurement phase
• Phase 4 – EPC contract construction, commissioning and handover phase

Rendel was involved during all stages of the project, including master planning, preliminary design, tender document preparation, tender review and the PMC role during phase 4 (construction supervision).

This included, but was not limited to, the following:

• Port planning, including an optimisation study comparing alternative forms of marine terminal for export of liquid and bulk products from the refinery
• Study option – shore connected jetty vs. sea island with submarine pipelines
• Definition of site investigations, supervision, bathymetric, metocean, design wave, vessel manoeuvring, berth occupancy/utilisation studies, and cost estimates
• Design and speciation documents for EPC phase tendering
• Review of the tenders received from marine contactors
• Costing and recommendations for appointment of contractors
• Review and approval of the EPC contractor’s design drawings
• Liaison with, and support to, environmental consultants
• Liaison with port authorities and third party stakeholders
• Supervision of the EPC contractor’s geotechnical studies, designs and marine construction