TAQAH

POWER AND

DESALINATION

PLANT

SAROOJ CONSTRUCTION COMPANY

Quarterly Newsletter Volume 3, Issue 2 Apr - May - Jun 2011

IN THIS ISSUE: SC-56 POWER AND DESALINATION PLANT IN TAQAH, PROJECT BACKGROUND AND SCOPE,

EXCAVATION UNDER SEA BOTTOM, INTAKE HEADS, INTAKE PIPES-OFFSHORE AND ONSHORE,

OUTFALL PIPES, PROJECT CHALLENGES, ON-SITE WORKFORCE, SAROOJ COMPANY NEWS, AND

BERLIN GLOBAL WATER AWARD 2011

Message From the General

Manager...

Dear Colleagues,

I am delighted to see the progress Sarooj

is making on the various fronts. Our sites

are performing better, our clients and

consultants are satisfied, and our safety

performance is improving all the time.

Quality management remains, however, the

big winner. The recent accreditation follow-up

by Bureau Veritas and the commendation

from our eminent client OOCEP are a bright

demonstration of your achievements.

It is in this way, by improving every day a bit

on everything we do, that we shall construct

excellence.

It is by trusting and developing the talents

and skills of the national workforce that

we achieve sustainability. It is by working

harder and more efficiently that we affirm

our position as one of the leaders of the

construction industry in Oman.

Sarooj Construction Company may look as

a family business within Al Taher Group,

it is in reality a family for all of its good

employees.

Jad Karam

General Manager

CONTENTS

SC-56 Water and Desalination Plant Pg 3

SC-56 Project Background Pg 4

SC-56 Project Scope Pg 5

SC-56 Excavation Under Sea Bottom Pg 6

SC-56 Intake Pipelines Pg 7

SC-56 Outfall Pipelines Pg 8

SC-56 Project Challenges Pg 9

SC-56 General Project Data Pg 10

SC-56 Project Depictions Pg 11

SC-56 On-site Workforce Pg 13

Sarooj News Pg 14

Global Water Award 2011, Berlin Pg 15

Project Sign Board

Blasting Under Water

SC-56 POWER AND DESALINATION PLANT

The Project:

Power and Desalination Plant in TAQAH

Intakes and Outfalls

The Client:

IPWP - SEMCORP

The Main Contractor:

EPC - SEPCOIII

Location:

TAQAH, Dhofar Province

Contract Duration:

6 Months

Project Value

12 Million US Dollars

OVERVIEW

3

ThE PROJECT

BaCKgROuNd

Demand for power and water has been increasing at a rapid rate (about 10% annually) since the beginning of the

Renaissance in the early seventies. The Ministry of Electricity and Water, at that time, was in charge of providing

the country’s needs.

Some fifteen years ago, the government in Oman decided to privatize the production of power and water. Interested international parties participated to tenders for that purpose.

Presently there are private operators who produce power and /or water in Manah, Barka I, II and now III, in

Al Kamel, in Sur, in Rusayl, and in Sohar I and II.

SEMCORP, as an independent power and water producer (IPWP), were awarded the contract to build a 460MW

power station in Taqah, in the Dhofar Province combined with a desalination unit capable of producing 15

million gallons of water per day. The EPC (Engineering Procurement and Construction) contractor selected for

the works was the Chinese government- owned company SEPCO III, who commissioned SAROOJ to carry out

SC-56 THE PROJECT

Pre-Launching

Kumzar Loaded with Head

Excavation after Blasting

The Flotilla

the intake and outfall structures in the sea, together with

all interconnecting pipelines on land.

4

SCOPE

SAROOJ works consisted primarily of the construction of two intake heads, placed some 600M off-shore and

twin 1400mm diameter HDPE intake pipelines (Heavy Duty Poly- Ethylene) from the heads to the pumping

station and then from the pumping station to the main plant, built on a plateau overlooking the sea, using GRP

pipes (Glass Reinforced Pipes). The outfall arrangement consists also of GRP pipes buried deep in the rock, an

open cascade, an outfall pipe 1600mm diameter, and a diffusing structure.

TEmPORaRy JETTy

In order to operate off- shore and shelter the marine

vessels, the project manager, Gerben Overal, decided

to build a temporary jetty with a quay wall facility so

that vessels can come close and moor to be loaded

with equipment and materials. As the plateau consists

of layers of limestone, excavated rocks, available on

site, were sorted and used to build the temporary

jetty and protect it from sea action.

SC-56 PROJECT SCOPE

Welding Joints Inside the Pipes

Welding Joints from Outside

Installing Intake Pipe

Outfall Pipe Excavation

5

SC-56 PROJECT PROCESS

ExCaVaTION uNdER SEa BOTTOm

As expected the sea bottom proved to consist of very hard limestone stratas that extend for long distance. A shallow sandy overburden

covers the rock. At an early stage it became obvious that blasting the rock with explosives was the only way to complete the work on time. It

took quite a while to process the necessary permits and obtain the concerned authorities’ approvals, particularly the Ministry of Environment

and Climatic Affairs

(MECA) and the

Royal Oman Police

(ROP). Sarooj used

the services of their

habitual blasting sub-

contractor D̀etonator LLC΄. Explosives were stored in an existing

ammunition depot

in Thumrait,150km

away from site, and

controlled by ROP.

On- shore and on the

temporary jetty the

drilling for blasting was

done by Geosol, our

sister company, using

drilling rigs, mobile on

crawlers (Soilmech).

Drilling under water,

which was limited to

the excavation of pits

to receive the intake

structures and the

outfall diffuser was

carried out by divers

using hand- drills. The blasting patterns were carefully worked out to minimize the bang and avoid possible damage to the close-by power house. Several measures were taken to minimize the impact on the environment and marine life.

All excavation had to be completed before any permanent works are done, precisely because of the blasting operations. Excavated

materials were loaded on self-propelled crafts and carted away to land and then disposed of in an approved dumping area.

Concreting Under Water

Launching Intake Pipe The Pumphouse Steel Structure

6

ThE INTaKE PIPES

Off-ShORE

A thorough research was made to select the type of pipe that

was most suited for site conditions, delivery time and required

performance. Considering the severe sea action during Khareef,

the vigourous currents in the area, a solid but flexible material had to be chosen. It was decided to use HDPE pipes which could be

welded into long sections as opposed to the shorter rigid GRP

pipes. Two 1400mm diameter pipes were selected to ensure daily

delivery of 165,000m³

Sarooj submitted a detailed method statement for butt welding

of the pipes into lengths approaching 200meters, fixing concrete rings to counterpart buoyancy, launching and sinking, as per

manufacturer’s recommendations. KUMZAR, and GHUMAYS

were used for the operations. Divers connected the section of

pipes under water. DANA IV ensured supply of bedding materials

and rock armor protection once the pipes were sunk into position.

The two intake pipes that started at the intake heads (each pipe

connected to one intake head) were connected to the pumping

station located on the beach. Furthermore, chlorination pipelines,

150mm in diameter, also in HDPE were laid alongside of the intake

pipes, in a similar way.

As the intake pipes were to withstand 0.4 bar negative pressure,

verification calculations were made in Germany by KRAH engineers, KRAH being the patent holder. The pipes were

manufactured in UGPM’s ultra- modern factory in Rusayl (Union

Gulf pipe Manufacturing LLC).

SC-56 PROJECT INTAKE PIPELINES

Escavating Trench

Temporary Jetty

Cascade StructureA Little Rest on the Platform

Manitowoc Lifting the Head

ON-ShORE

From the pumping stations to the main plant, smaller diameters

GRP pressure pipes were used to convey the water. The profile of the pipeline route was particularly steep in the section going

up the cliff face to reach the plateau.

7

SC-56 PROJECT OUTFALL PIPELINES

ThE OuTfall PIPES

The brine is taken through GRP pipes on the plateau,

buried deep in the rock, until the edge of the cliff by

the beach. The water would then be released into a

cascading concrete structure, built in several steps

before it is collected in a chamber on the beach

and taken out in the sea through an outfall pipeline,

HDPE, of 1600mm diameter. On-shore pipes were

laid length by length and off- shore pipe by welding,

launching and sinking.

Outfall Pipe-GRP on Land

Outfall Pipe - JointsOutfall Pipe - Launching Area

Outfall Pipe - HDPE in the Sea

dIffuSER

The concrete diffusing structure was precast

on-shore and transported on to the temporary

jetty and then taken by KUMZAR to its final location.

8

IN- SITu ROCK:

The presence of rock where the structures and pipeline

were to be buried, necessitated to go into the process

of obtaining underwater blasting permit. This required

detailed environmental impact studies, special drilling

equipment, coordination with ROP (Royal Oman Police)

for escorting explosives supply and attending blasting

operations, safety measures, storage of hazardous materials and protection of other parts of the project.

ROCK aRmOuR:

Sarooj identified a good source of rock about 60km away from site. Test run by third party proved satisfactory.

Although large quantities of broken rocks were generated

and stored on site, and despite the fact that some stratas of the sedimentary limestone forming the plateau were

of high quality, the non-consistent stock could not be used for permanent works. Sarooj use them, however, to

build temporary works such as the jetty.

SC-56 PROJECT CHALLENGES

ChallENgES

Sarooj project team faced several challenges and found

suitable solutions for them:

COmmuNICaTIONS:

as it was the first time Sarooj worked with a Chinese company, they faced an acute communication problem.

It was not only the language but also the culture.

Notwithstanding the fact that Chinese people are pleasant

individually, they have a different culture and ways of

managing their business. Sarooj had to understand and

adapt.

WEaThER:

The project is in TAQAH in Dhofar province. The area falls under annual monsoon regime, when for several

months the sea becomes continuously rough and develops big waves reaching up to 6 to 7m in height. Therefore,

the off-shore activities and consequently the construction programme are deeply affected by Khareef and had to

be constantly reviewed and adjusted.

The Coastal Cliff

Lifting Ring Designed In-House by Charbel Abou SamraKumzar

The Monsoon

9

SC-56 PROJECT OVERVIEW

marine Equipment used

Crane on barge Sumitomo Crane

250T on KUMZAR

Landing Craft Ghumays

Landing Craft DANA IV

Landing Craft DANA VI

Tug Boat Hud Hud

general Project features

Length of intake pipes (off-shore) 1200 l.m.

Diameter of Intake pipes (off-shore) 1400 mm

Number of Intake structure 2 Nos

Type of pipes HDPE

Capacity of pumping station 165,000m³ per day

Length of Intake pipes (on-shore) 3000 l.m.

Diameter of intake pipes (on-shore) 800mm, 600mm, 400mm

Type of pipes GRP

Length of out fall pipe (off-shore) 300m

Diameter of out fall pipe (off-shore) 1600mm

Type of pipe HDPE

Other out fall pipes (on-shore) 1000m

Type of pipe GRP

Construction period 6 months

10

SC-56 POWER AND DESALINATION PLANT

Outfall Pipe area mr. Qu Wu Visits the Site

The Pump house

Kumzar lifting for launching

11

Our director with the Client The Temporary Quay Wall

Bringing Pipes Together for Welding

Outfall Cascade another Blast

SC-56 POWER AND DESALINATION PLANT

12

ON SITE WORKFORCE

mudaThER aSWad

Project Engineer (Civil)

gERBEN OVERal

Project Manager

few of the Team

mOhammad KhuNJI

Project Engineer (Marine)

BISWaS PaTEl

Marine Supervisor

13

SAROOJ NEWS

COMPANY NEWS

• Both the managing director and the director paid a five–day visit to Iraq where they met high government dignitaries and investigated possible business opportunities

in that promising market.

• Sarooj has now an office in Abu-Dhabi which will soon be operational.

• We were awarded the contract to carry out the piling works for the “Wave, Muscat” Marina.

• Sarooj jointly with Taylor Woodrow submitted a bid for the construction of three light houses and DGPS stations along the Omani eastern coast. The joint ventures

are the lowest Tenderer (L1).

• A team from Ferrovial visited Sarooj for two days to familiarize themselves, with the B̀atinah Expressway- Package΄ project in preparation of the joint bid that both companies intend to present.

• Richard Willshaw is settling down in his position as commercial manager. We wish him good luck.

• The MGP team (Musandam Gas

Plant) has started

their mobilization to site and camp

construction is on its

way.

• The works on Phase II of the Nimr

Water Treatment

Plant has started.

14

PRESS RELEASE

GLOBAL WATER AWARD 2011, BERLIN

Kofi Annan presents Global Water Award 2011 to BAUER Water

BAUER Water GmbH

• Berlin - The Global Water Awards Ceremony 2011 was held on 18th April 2011 at the Global Water Summit

in Berlin. The innovative reed bed treatment plant,

designed and built by the Bauer Resources subsidiary

BAUER Water and treating around 45,000 m³ of oil-

contaminated water daily in Oman, surpassed three

other shortlisted projects and was awarded the first prize for the most impressive technical achievement in the category ‘Industrial Water Project of the Year‘. The

keynote speaker was the former UN Secretary General

Kofi Annan who also presented the awards.

• On accepting the prize from Kofi Annan, Dr. Roman Breuer, responsible Project Engineer of BAUER

Umwelt GmbH declared: „We are extremely delighted

to receive this award as the entire team of BAUER

Umwelt GmbH has worked tirelessly during the last four

and a half years towards the success of the project.“ He was accompanied by Peter Hingott, Manager of

Bauer Resources Environment Division, Joachim Huth,

Management Board member of BAUER Water GmbH

and Wolf-Dieter Rausch, Planning Engineer of BAUER

Nimr LCC.

• Congratulations were also offered by Dr. Michael Bornmann, Management Board member of the

German Investment and Development Corporation

(DEG): „We would like to offer our sincere congratulations and are pleased that this project, which is exemplary in

terms of environmental and development policy, has gained recognition in this way.“ The reed bed treatment plant was financed with the support of DEG and the project was nominated by the World Business Council of Sustainable Development (WBCSD) of Geneva.

• Since 28th November 2010, exactly two years after the day of contract award by the client, Petroleum Development Oman (PDO), the so-called produced water flows from the near-by Nimr Oilfield into the largest commercial reed bed treatment plant in the world with an area of 235 hectares. The plant is currently treating around 45,000 m³ of

contaminated water every single day achieving a level of purification in excess of 99.5 percent. A few days ago, Petroleum Development Oman also finally confirmed that the existing contract is to be expanded to twice the water quantity. In future, the plant is to treat 95,000 m³ of contaminated water per day. In addition to this extension, the

project does further justice to its environmental mission by producing part of the construction material required for the

extension by cleaning oil contaminated soils from the oilfields.

Presentation of the Global Water Awards 2011 in Berlin: (from left) Simon

Karam (Sarooj Construction Company), Kofi Annan, Dr. Roman Breuer (BAUER Umwelt GmbH), Wolf-Dieter Rausch (BAUER Nimr LCC), Badar Al Sharji (Petroleum Development Oman), Joachim Huth (BAUER Water

GmbH) and Peter Hingott (Bauer Resources Environment Division). (Picture by courtacy of Global Water Intelligence) www.bauer.de/en/press/press_

articles/2011

15

Sarooj Construction Company LLC ● P.O.Box 1413, Postal Code 112 ● Ruwi, Sultanate of Oman.Telephone: (+968) 24 596001 ● Fax: (+968) 24 596011

www.sarooj.com ● info@sarooj.com

CONSTRuCTINg

ExCEllENCE

Fo

r p

riva

te c

ircu

latio

n o

nly