2NAZIIDCP Opening Presentation

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 OfThe 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 Building’s 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 VDF’s 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 PlantFinal Approved Perspective

Main items forming the basisof 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 / MDB’s 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 Client’s 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 3rd August 2006

Site Possession Date 26th August 2006

Completion date 31st December 2010

Project Value Over 210 Million Dollars

Start Of Chilled Water Supply From

Plant

23rd 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 UDC’s 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 PlantFinal (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