WorleyParsons’ Role and Facility Overview
WorleyParsons has two major contributions to this development; first through the management of the $4.5 billion (direct capital cost) Phosphate Project and second through the management of development of the minerals complex infrastructure including a bachelor housing village, common utilities such as cooling water, and oversight of the deepwater port being developed by the Saudi Seaport Authority. The Phosphate Project being managed by WorleyParsons is focused on the economic development of the major phosphate rock resource located at Al Jalamid. The fertilizer complex at Ras Az Zawr, which is also being managed by WorleyParsons, will produce three million tonnes of DAP each year, which represents over 10% of the world production of DAP.
Magnitude of the Development
The full development project involves the design and construction of some of the largest facilities of their type ever built, particularly the three sulfuric acid plants and the three phosphoric acid plants. The upgraded plan for the ammonia plant will result in it too being the biggest in the world.
Global Talent Focused on Single Mega Project
While projects are increasing in size and complexity around the world, they are rarely executed from a single location. WorleyParsons’ approach to the Ma’aden development highlights the requirement of appropriate global expertise working in a synchronized manner to deliver a diverse and detailed range of EPC packages to the international contracting market. A central team, stationed in Al Khobar, has worked closely with Ma’aden and the relevant Saudi Arabian authorities. Melbourne provided the detailed design of the utilities and offsite (U&O) at Ras Az Zawr and FEED services for the beneficiation plant at Ras Az Zawr. Singapore completed the FEED for the balance of plant and master plan for the power component at the Al Jalamid site. Perth completed the master plan for the Ras Az Zawr site including the phosphate, alumina, aluminium facilities and civil infrastructure, and the detailed design for the seawater intake. Al Khobar and Bahrain provided procurement support for the U&O. Beijing provided design support for each of the offices. Collectively over 350 personnel, including 180 in Al Khobar, in five global offices, were devoted to successfully ensuring all the packages were released to the market and that control of the execution strategy was maintained.
Successful Engagement of World-Class Contractors
WorleyParsons’ Project Management Consultancy (PMC) role involves the creation and development of work packages to ensure comprehensive and timely development of the proposed facilities and then support services for the selection of the best international contractors to execute the packages. Major components of the development program are being executed in Seoul, Korea; Beijing, China; Gwiwang, China; Milan, Italy; Madrid, Spain; Frankfurt, Germany; Chicago, USA; and Melbourne, Australia. The challenge of ensuring exemplary quality performance by all the EPC contractors working in multiple languages and time zones has been embraced by the Al Khobar team.
Training and Development Commitment
Since WorleyParsons first commenced operations in Saudi Arabia in the 1970s, it has been committed to the “Saudisation” of the workforce, where Saudi nationals are trained and developed to undertake senior roles within the business. A number of Saudi nationals have been relocated to Pasadena, Frankfurt, Milan, Madrid, Gwiwang, Melbourne, Singapore and Seoul to further their international expertise.
Sustainability
All project facilities have been engineered to meet or exceed global environmental standards. The facility at Ras Az Zawr will be self‑sufficient for power and water.
HSE Commitment
At its the peak the construction site at Ras Az Zawr will host over 12,500 workers from more than 15 contractors. A majority of the construction teams comprise workers from India, Pakistan, Sri Lanka, China and North Africa. The coordination of these teams to ensure safe performance is a constant focus for the WorleyParsons team and new standards are being set within the country for HSE management. Significant programs are in place to overcome communication and cultural barriers, job hazard analysis and risk analysis programs have been implemented and a reward program approved by the owners and chief contractors.
