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Challenges Presented by Brownfield Sites to Major Projects

Challenges Presented by Brownfield Sites to Major Projects. Berlin, Germany. Annraoi Caffrey, ESBI Project Manager & Finbarr Quigley, ESBI Senior Consultant. 30th March 2012. ESB International in brief…. A multi-disciplinary engineering, consultancy and O&M business 1,100 employees

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Challenges Presented by Brownfield Sites to Major Projects

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  1. Challenges Presented by Brownfield Sites to Major Projects Berlin, Germany Annraoi Caffrey, ESBI Project Manager & Finbarr Quigley, ESBI Senior Consultant 30th March 2012

  2. ESB International in brief… • A multi-disciplinary engineering, consultancy and O&M business • 1,100 employees • Annual turnover approx €110m • Projects completed in 115 countries • Current operations in >20 countries • Wholly owned by ESB Group (Irish state-owned) 35 Year Track Record in International Consultancy

  3. ESB International - Locations

  4. ESB International - Locations

  5. ESBI Recent Projects • Dublin Bay Power, Ireland • 412MW CCGT • Commercial Operation 2002 • Brown Field • Amorebieta, Spain • 755MW CCGT • Commercial Operation 2005 • Green Field

  6. ESBI Recent Projects • Coolkeeragh, Northern Ireland • 400MW CCGT • Commercial Operation 2006 • Brown Field • Marchwood, Southampton UK • 840MW CCGT • Commercial Operation 2009 • Brown Field

  7. ESBI Recent Projects • Aghada, Cork, Ireland • 435MW CCGT • Commercial Operation 2010 • Brown Field • Carrington, Manchester, UK • 860MW CCGT • NTP 2012 • Brown Field

  8. Good infrastructure connection • Gas Transmission System • HV Grid • Transport Routes • Residual Site Risks • Contamination • Existing services and structures • Disruption to existing industrial stakeholders • Cooling • Existing Cooling Source • Reduced Capex • Environmental • Suitable for CCR/ S • Availability of land Benefits vs Challenges of Brown Field • Good planning context • Reusing Brownfield Site • Industrial zoning • Visual impact • Regeneration 800-1500MW CCGT

  9. The Carrington Project

  10. Original Coal Fired Station

  11. WaterSource Gas Supply HV Substation Site Overview

  12. Proposed Development

  13. Key Challenges Experienced • Route for Gas Pipeline • Existing Buried Structures • Contamination • Invasive Plant Species

  14. Routing of Gas Pipeline

  15. Power plant site Pipeline • 2.4km • Welded steel • 600mm dia • 19.1mm thick • 70barg Carrington Gas Supply

  16. 1.2km

  17. Canal Landfill Culverts Canal Culvert

  18. Canal Landfill Culverts Canal Landfill Culvert Canal Culverts

  19. Canal Landfill Culverts Canal Culvert

  20. Horizontal Directional Drill

  21. Horizontal Directional Drill Ground Level Entry Culvert Structure Exit 30m 1200m long drill Bedrock

  22. Pipeline Outcome • Financial Commitment prior to Financial Close • Engineering Resource Requirement • Extension of Develop Phase Programme • Pipeline detailed design contract • Proved viability of pipeline route • Detailed design available • Significant Saving on Pipeline Construction Contract relative to Design & Build • Risks addressed thus reducing Client’s exposure (time & cost) • Project Value Increased Risks successfully addressed prior to award of fixed price construction contract

  23. Buried Structures - Identifying - Removal - Mapping

  24. Site Issues • Existing foundations supported on piles • Inadequate drawings of foundations • Very limited information on ground conditions • Contamination Issues • Localised hotspots • Japanese Knotweed • Asbestos • Existing HV cables and drains crossing the site

  25. Original Coal Fired Station

  26. Site Overview

  27. Solution Options • Option 1 • Include in EPC Contract scope • Single all inclusive contract Option 2 Prep work in advance of the EPC Contract Client invests upfront to manage risk • Option 2 Selected with the following objectives: • Provide Information for EPC Contract Negotiation • Prepare Site for handover to EPC Contract

  28. What we did?

  29. Foundations more extensive than Desktop Study

  30. Additional existing piles -Original estimate 3,500 - Final total 5,579

  31. Proven Methodology Risk Workshops Project Risk Logs Geotechnical Risk Log Lessons Learnt Reviews & Log Safety Workshops Zero LTI Goal Safety Initiatives Interactive Safety Workshops with Contractors High Level Steering Committee Contract Delivery

  32. Buried Structures Outcome • Financial Commitment prior to Financial Close • Engineering Resource Requirement • Extension of Develop Phase Programme • Significant Saving on Cost relative to that proposed by EPC • Significant Variation in scope • Risk addressed thus reducing Client’s exposure (time & cost) • Proposed Design now Site Specific • Site Value Increased Risk successfully addressed prior to award of turnkey fixed price contract

  33. Conclusion Experience Lessons Learned Project Delivery Methodology Advance Works Robust Project Risks mitigated Fixed price construction contracts

  34. Thank You Any Questions?

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