Integrated District Cooling Plant at The PEARL

The World Largest District Cooling Plant

Project Name: IDCP
Employer : QATAR Cool
EPC CONT. :C.A.T. INTERNATIONAL
DESIGN S/C :SCI
PMC : DAR AL HANDASAH
TECHNICAL CONTROLLER: BVI
THE WORKS
The works are executed as an EPC contract and
comprise the design, supply, delivery, erection and
installation on site of a district cooling plant with a
guaranteed capacity of 103500 expandable to
113,500 tons of refrigeration and associated heat
exchanger facilities at various locations serving the
entire island of the Pearl Project complete with all
associated building work including architectural and civil
engineering work and all necessary electromechanical
equipment, all as more fully described and shown in the
drawings and in Volumes 3 to 6 of the Tender and
Contract documents.
Estimation Challenges Of
The World Largest District Cooling Plant
Minor process feed design
No Civil Design
No MEP Design
Value Engineering required by Client
Different options required for:
- Space Reduction
- Best Output (TR)
- Reduced KW/TR Power
Consumption
C.A.T. submitted 6 Alternatives
Different Architectural Layouts.
Different Process Design: - Glycol Chillers
- Ice storage tanks
- Thermal storage tanks
- None of the above
Different Chiller Modules:
- 2 X 2500 TR
- 1 X 5000 TR
- 3.3 KV - VS 11 KV
Changed the Pumping Scheme: Constant speed VS Variable
Speed
Maintained required Power Consumption.
Minimized the Buildings Foot Print.
Selected Alternative Benefits
Increased Plant output by 25,000 TR to a Total of 130,000 TR.
Shifted condenser pumps to roof Less space required.
Reduced Cost by eliminating VDFs for pumping which is valid, in IDCP case,
as 5 000 TR module / step represents only 3.85% of the Plant Capacity.
Substituted complex control scheme by staging chillers / pumps
based upon DP ( Cooling Load ).
Guaranteed Less Than 1 KW / TR of Power.
Plant operational on potable / RO / TSE water.
Energy Saving by using Primary only pumping scheme.
Located Chillers on ground Floor Less Structural complexity.
Diversified milestones ( Multiple of 5 000 TR).
Reduced The Plant Footprint.
Shortened the project schedule.
Pumping Scheme Comparison summary
Primary Secondary Benefits Direct Primary Pumping
Benefits
Simplified controls and operation Flexible & Efficient controls and
operation
Wide spread experience among
plant operators
Reduction in number of Equipment
& pumps i.e., less Operators
required
Smaller motors and less impact to
building system design pressure.
Potential reduction in plant capital
and operating costs
Clearly, the Benefits of the direct- primary pumping system allow much greater
flexibility for the operators in providing chilled water where it is needed in the
most efficient manner possible. However this system is more complex and
requires training and understanding of how it is to operate.
Even though primary secondary systems remain the more comfortable
choice direct primary systems are picking up momentum as the preferred
operational scheme.
A.
B.
C.
D.
E.
HEALTH, SAFETY & ENVIRONMENT
C.A.T. Group of Companies places paramount importance on Health, Safety and
Environmental issues. We continually strive to eliminate risk of accidents, incidents and
loss with regard to both Client and C.A.T. Personnel & Property
C.A.T. prides itself on its long construction industry experience which spans some 75
Years and our excellent record where Health, Safety & Environmental performance is
concerned.
C.A.T. Operations are conducted in line with a group wide "Occupational Health and
Safety Management System" developed & implemented according to OHSAS 18001:2007
IDCP Project was planned & executed with industry "Best Practices" methods to achieve
the highest performance in both Safety & Quality
We will continuously work to improve our performance through management involvement,
employee participation, client & peer critique and proactive approaches
Total number of LTI x 200,000
Total man-hours worked
Total days lost x 200,000
Total man-hours worked
0.09
0.91
IDCP PROJECT SAFETY STATISTICS
2. ACCIDENT FREE MAN-HOURS 5,428,647
(September 2006 - October 2010)
(No LTI since May 2008)
1. TOTAL MAN-HOURS WORKED 8,781,693
4
3. NUMBER OF FATALITIES 0
6. SEVERITY RATE
5. FREQUENCY RATE
4. NUMBER OF LOST TIME INCIDENTS
Integrated District Cooling Plant
Final Approved Perspective
Main items forming the basis
of Value Engineering
1. Chillers: - Size
- No. of compressors
- Voltage
2. Chilled water design conditions
3. Condenser water design
4. Cooling Tower capacity per cell
5. Thermal storage
6. Pumping scheme
7. Building Height / Louvres & Air Intake
8. RO Plant
9. Building HVAC
Brief Description:
Scope : Design, Supply, Delivery, Erection,
Testing and Commissioning
Service : The Pearl Island
Mechanical Process:
Series-Counter Flow Chillers Train Arrangement
Modules arranged in 5,000 TR
52 Chillers X 2,500 TR, each, producing 130,000 TR
26 Chilled Water Pumps (26 X 7,500gpm)
26 Condenser Water Pumps (26 X 11,500gpm)
26 Cooling Towers (26 X 10,000 TR)
120 Plate Heat Exchangers
More than 12,000 Meters of Process pipes inside the Building
Building Services for Plant and for 35,000 M3/day RO Plant
COOLING TOWERS
1 PAIR CHILLER MODULE
Electrical & Controls Process :
170 MW Station (120 MW For Operation)
43 Transformers 66KV/11KV, 11KV/3.3KV
43 MCC / MDBs 11KV, 3.3KV & 415V.
130 Hi Voltage Motors of 3.3KV.
More Than 260,000 Meters of Cables.
More Than 55,000 Meters of Raceways.
Advanced SCADA System
Remote Monitoring of CHW Delivery at Clients side
Civil Structure
Multi Story Design
203 M long X 75 M WIDE X 34 M High Building
36 ETS Rooms & 17 HEX Buildings
16,000 M2 approximate Floor Area
48,000 M2 approximate Built Area
80,000 M3 + of Reinforced Concrete
Shoring, Excavation, Dewatering, etc..
Important Data
Notice To commence date 3
rd
August 2006
Site Possession Date 26
th
August 2006
Completion date 31
st
December 2010
Project Value Over 210 Million Dollars
Start Of Chilled Water Supply From
Plant
23
rd
July 2009
Progress Distribution
ITEM DESCRIPTION
ACCOMPLISHMENT
(MANHOUR BASED)
WEIGHT
FACTOR
1 GENERAL 13%
2 ENGINEERING 2%
3 PROCUREMENT 6%
4 CONSTRUCTION 79%
OVERALL 100.000%
Manpower
Temporary Equipment & Plant
IN EXCESS OF 250 EQUIPMENT &
PLANT UNITS WERE USED ON THE
JOB, INSIDE THE BUILDING, FOR
CONSTRUCTION
Detailed Engineering and
Shop Drawings
Total Number
of Drawings
Total Design Drawings 617
Total Shop Drawings 1,063
Overall Total 1,680
Activities Subcontracted
All the Works were executed by C.A.T. International
except for the following Subcontracts:
Dewatering & Waterproofing
Precast Concrete
NDT
SCADA & Controls
GRC Works
Doors, Aluminum and Glazing
Major EPC challenges
Design develop. while construction is going on at EPC Cont. Risk.
Select Vendors and get material approved while developing design
Entertain Client increasing load requirements
Establish on site design Team besides overseas design
Place orders, with high Risk, to avoid escalation of materials prices
and currencies, noting that 85% of Material was imported.
Limit the design in line with the orders
Deliver the Material in a Timely Manner.
Establish 9000 M2 of workshops & 15000 M2 of Lay down Area &
Storage
Hire skilled and experienced labor from Middle East and Far East.
Mobilize 800 Qualified men in 5 Months.
- Client changed chillers Selection (R134a instead of R123) in order to meet
environmental requirements.
- Excavate and Construct 10 meters below sea level due to a larger RO
Plant.
- Develop the Luxurious Building Design requirement of UDC, blending
with The PEARL surrounding Buildings identities, and integrate in the same
a Large Heavy Industrial Plant, all while Construction is Proceeding,
resulting into changing the Building Perspective more than 6 Times.
- Meeting UDCs Construction & HSE Regulations, Permits Procedures
established specifically for the PEARL Island and their demanding &
Complex Coordination needs with other Contractors.
- Collaborate with Qatar Cool to implement the above requirements while,
at the same time, offering them a feasible Project that matches their
Financial Model.
- Operate part of the Plant (30%) while still Constructing the rest of it.
- Provision of offsite Temporary Chillers (2,500 TR) For Buildings which
were ready Before the Plant Operation.
Integrated District Cooling Plant
Final (executed) Perspective
- DYNAMIC PLANNING
- TRANSPARENT COMMUNICATION
- TEAM WORK: EMPLOYER / EPC CONTRACTOR / PMC
- CONTINUOUS RESOURCES BUILT-UP.
Project Name : IDCP
Client : Qatar Cool
PMC : DAR AL HANDASAH
TECHNICAL CONTROLLER :BUREAU VERITAS
EPC Contractor : C.A.T. INTERNATIONAL