The Successful Construction of DC Plants: Saadiyat Island Case

Transcription

1 The Successful Construction of DC Plants: Saadiyat Island Case A toolkit for overcoming challenges through Project Structuring, Value Engineering, Shared Expertise & Practical Minds 26/11/2013 )

2 Summary a real partnership PROJECT STRUCTURE Advantages of long term solutions (BOOT, DBO) PROJECT DELIVERY Various contractual frameworks VALUE ENGINEERING Technical Considerations CONSTRUCTION CHALLENGES Permitting, regulations, BENEFITS FOR ALL STAKEHOLDERS 2

3 About ADC Energy Systems 1 core sector (District Energy) 1 core expertise (EPC) AED 600 m in Projects under construction EFFICIENT EPC CONTRACTOR 16 Plants Completed or Under Construction 1 EPC Contractor Focused solely on District Energy Plants Over 5,000,000 = only 200 Man- Days lost in minor accidents Man-Hours SECTOR FOCUSED 8 Major Utility Developers as Clients 0.5 Million tons C0 2 emissions avoided each year = 4,166 EARTH HOURS 2013 IN DUBAI OR NEARLY ½ YEAR OF Closing on 500,000 Tons of Refrigeration Plant Capacity PROJECT MGMT EXPERTISE AED 1.6 Billion worth of Past & Current Projects Concurrently Building Plants in 3 GCC countries >600 employees EOY

4 About Dalkia A SUBSIDIARY OF EDF AND 3 core businesses (Water, Waste and Energy) 29.4 b in revenues 200,000 employees SUSTAINABLE PERFORMANCE 14.4 TWh ENERGY SAVINGS 50% electricity annual consumption of a country like Ireland Almost 13 % renewable energy (out of which 3.4 Mt biomass) 7.5 Million tons C0 2 emissions avoided = = Global emission in a city like Paris 133,000 energy sites managed More than 800 heating and cooling networks More than MW heating capacity A UNIQUE EXPERTISE A KEY PLAYER 8.9 billion revenue in 2012 Operating in 35 countries 49,800 employees incl 2,000 in GCC 4

5 Saadiyat island Development Saadiyat Cultural District Saadiyat Marina Saadiyat Beach Saadiyat Promenade Saadiyat Retreat Saadiyat Lagoons Saadiyat Reserve Master Developer: Tourism Development & Investment Company (TDIC) Saadiyat Island is a US$ 27 billion mixed-use development being developed as a cultural and touristic destination for the Abu Dhabi emirate, with a total builtup area of over 1.6 million m2 and which is comprised of: Saadiyat Cultural District (Louvre, Guggenheim, Zayed National Museum) Saadiyat Beach (St Regis, Rotana, Park Hyatt) A variety of residential and hospitality centric developments 29 Years concession for 3 District Cooling Plants with a total capacity of 70,000 TR. 5

6 Project Structure: an integrated solution Customer / Plot 1 Equity Investor Customer / Plot 2 Customer / Plot 3 Customer / Plot 4 Customer cooling agreements Concession agreement (29 years) Asset Co. (concession company) EPC contractor Phase 1: (Engineering, Procurement and Construction) (Operation & Maintenance / Asset) (Development & Management Services) Operating company 6

7 Project structure: Advantages of long term solutions The advantages of long term project structures such as Build-Own- Operate-Transfer (BOOT) or Design-Build-Operate (DBO) project structure, with minimum durations of 20 to 25 years are: Long term partnership: add value to the project through continuous improvements Single point of contact: easier to be managed for the master developer Involvement of the Operator during the construction and commissioning: ensure proper handing over between the Contractor and the Operations team Responsibility on the energy performance of the plant: the developer or client can budget precisely the utilities cost Commitment to maintain the assets in the best condition: increase the life time of the plant Cost effective over a long term: optimization of construction and operations constraints. Financing of the assets by the DC provider (BOOT option) TDIC awarded the District Cooling Concession to a consortium led by Dalkia on a BOOT project structure for a duration of 29 years. 7

8 Project delivery methods Once awarded the District Cooling concession, the DC Provider needs to contract with a specialist EPC Contractor. Two different methods: Design-Bid-Build (DBB): Owner / DC Provider develops contract documents consisting of a set of blueprints and a detailed specification. With possible help from a construction manager to act as an agent Engineer-Procure-Construct (EPC) or Design & Build (DB): Owner / DC Provider develops a conceptual plan for a project, then solicits bids from EPCCs to handle the design, procurement of all equipment & construction materials, and construction services for turnkey delivery of the facility, usually at a lump-sum price (LSTK). Dalkia selected the second option and awarded the DB Contract to ADC after a competitive process: All parties collaborated for optimal project performance and companies benefited from tightest integration of activities during the value-based construction process. ADC s best practices approach and staff focused on identifying and resolving issues early allow the design work to remain on schedule and to purchase at the right time the long-lead equipment and materials. Owner reduced its risk of expensive change orders by continuously and dynamically coordinating with ADC 8

9 Functional Framework DISTRICT COOLING PLANT #1 DISTRICT COOLING PLANT #2 DISTRICT COOLING PLANT #3 PROJECT MANAGEMENT DALKIA DESIGN ENGINEERING PROCUREMENT & CONSTRUCTION PHASE 2 TBA ADC ENERGY SYSTEMS ENGINEER SITE SUPERVISION DALKIA 9

10 Salient features of the plant Apart from the standard design features, Saadiyat DC plant also include the following additions: 100% redundancy on Transformers and spare supply feeders Bus bar redundancy on every voltage level N+1 redundancy on all pumps and Thermal Energy Storage to accommodate the peak load and can act as a buffer Interconnections with future DC plants Standby genset to operate secondary pumps with thermal storage and network for continuous cooling under shutdown mode. Plant designed to be operated with Polished Treated Sewage Effluent (TSE) in the future Variable Primary-Variable Secondary chilled-water system Automation system designed to accommodate unmanned operations. 10

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12 Sound Engineering Practices Preconstruction efforts involved preliminary planning and engineering to finalize on the concept design and optimize the project schedule based on related specifications and owners requirements. Optimization of the layout of the plant to reduce size of the plant and optimize construction costs including reduction of the basement size Use of vertical in-line pump arrangement for main process pumps, such arrangement created more space in the plant room rather than basement. Implemented a low delta T syndrome mitigation: this implementation enhanced plant performance at low delta conditions: Variable Primary-Variable Secondary chilled water system. Equipment and piping conservative selection Phasing of plant equipment procurement and installation to align production with growing demand 12

13 Construction Challenges Worked hand in hand with Master Developer and DC Provider to mitigate delays and difficulties in: Receiving registered plots which are supposed to be ready for commencement the construction. Complying with changing regulations placed by authorities Reduction of project duration by use of pre-cast columns, beams and hollow core slabs in the superstructure in lieu of cast-in-situ Chillers installed on ground slab and erection of scaffolding around chillers and wooden planks to work around chillers. 13

14 Tangible benefits for all stakeholders End-Users & All Stakeholders Integrated Project Delivery method between the Master Developer / DC Provider / EPC Contractor resulted in a collaborative, value-based process delivering high-outcome results and meeting the interests of the team members. Master Developer Reduced project risks Delivered projected results Maximized effectiveness of capital planning Utility Operator Highly efficient Plant: 0.85 kw/ton during performance tests Strong reliability to ensure lifetime operation and service to end-users EPC Contractor Learned more through the process Improved on Quality Control & Health and Safety internal practices and policies Built a reasonably profitable project 14

15 Thank you Contacts: Khalil Issa ADC Energy Systems Christophe Maquet Dalkia Utilities 15