www.esbi.ie

Challenges Presented byBrownfield Sites to Major Projects

Berlin, Germany

Annraoi Caffrey, ESBI Project Manager & Finbarr Quigley, ESBI Senior Consultant

30th March 2012

www.esbi.ie

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

www.esbi.ie

ESB International - Locations

www.esbi.ie

ESB International - Locations

www.esbi.ie

Dublin Bay Power, Ireland

•412MW CCGT

•Commercial Operation 2002

•Brown Field

Amorebieta, Spain

•755MW CCGT

•Commercial Operation 2005

•Green Field

ESBI Recent Projects

www.esbi.ie

Coolkeeragh, Northern Ireland

•400MW CCGT

•Commercial Operation 2006

•Brown Field

Marchwood, Southampton UK

•840MW CCGT

•Commercial Operation 2009

•Brown Field

ESBI Recent Projects

www.esbi.ie

Aghada, Cork, Ireland

•435MW CCGT

•Commercial Operation 2010

•Brown Field

Carrington, Manchester, UK

•860MW CCGT

•NTP 2012

•Brown Field

ESBI Recent Projects

www.esbi.ie

CoolingExisting Cooling Source

Reduced Capex

Environmental

Residual Site RisksContamination

Existing services and structures

Disruption to existing

industrial stakeholders Suitable for CCR/ SAvailability of land

Benefits vs Challenges of Brown Field

Good infrastructure connectionGas Transmission System

HV Grid

Transport Routes

Good planning contextReusing Brownfield Site

Industrial zoning

Visual impact

Regeneration 800-1500MW

CCGT

www.esbi.ie

The Carrington Project

www.esbi.ie

Original Coal Fired Station

www.esbi.ie

Site Overview

Gas Supply

HV Substation

WaterSource

www.esbi.ie

Proposed Development

www.esbi.ie

Key Challenges Experienced

• Route for Gas Pipeline

• Existing Buried Structures

• Contamination

• Invasive Plant Species

www.esbi.ie

Routing of Routing of

Gas Pipeline Gas Pipeline

www.esbi.ie

Pipeline

Carrington

Power plant site

• 2.4km

• Welded steel

• 600mm dia

• 19.1mm thick

• 70barg

Gas Supply

www.esbi.ie

1.2km

www.esbi.ie

Culvert

Culverts

LandfillCanal

www.esbi.ie

Culvert

Culverts

LandfillCanal

Culverts

Landfill

Canal

www.esbi.ie

Culvert

Culverts

LandfillCanal

www.esbi.ie

Horizontal Directional Drill

www.esbi.ie

CulvertEntry

Horizontal Directional Drill

Exit

Ground Level

Bedrock

30m

Structure

1200m long drill

www.esbi.ie

Pipeline Outcome

Risks successfully addressed prior to award of fixed price construction contract

•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

www.esbi.ie

Buried Buried

Structures Structures

- Identifying- Identifying

- Removal - Removal

- Mapping - Mapping

www.esbi.ie

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

www.esbi.ie

Original Coal Fired Station

www.esbi.ie

Site Overview

www.esbi.ie

Solution Options

Option 2 Selected with the following objectives:Provide Information for EPC Contract Negotiation

Prepare Site for handover to EPC Contract

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

www.esbi.ie

www.esbi.ie

What we did?

www.esbi.ie

www.esbi.ie

Foundations more extensive than Desktop Study

www.esbi.ie

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

www.esbi.ie

Contract Delivery

• 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

www.esbi.ie

Buried Structures Outcome

Risk successfully addressed prior to award of turnkey fixed price contract

•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

www.esbi.ie

Conclusion

Robust Project

Risks mitigated

Fixed price construction contracts

Experience

Lessons Learned

Project Delivery

Methodology

Advance Works

www.esbi.ie

Thank You

Any Questions?