Www.esbi.ie Challenges Presented by Brownfield Sites to Major Projects Berlin, Germany Annraoi...

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Challenges Presented byBrownfield Sites to Major Projects

Berlin, Germany

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

30th March 2012

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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

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ESB International - Locations

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Dublin Bay Power, Ireland

•412MW CCGT

•Commercial Operation 2002

•Brown Field

Amorebieta, Spain

•755MW CCGT


•Green Field

ESBI Recent Projects

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Coolkeeragh, Northern Ireland

•400MW CCGT


•Brown Field

Marchwood, Southampton UK

•840MW CCGT


•Brown Field


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Aghada, Cork, Ireland

•435MW CCGT


•Brown Field

Carrington, Manchester, UK

•860MW CCGT

•NTP 2012

•Brown Field


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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

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The Carrington Project

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Original Coal Fired Station

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Site Overview

Gas Supply

HV Substation

WaterSource

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Proposed Development

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Key Challenges Experienced

• Route for Gas Pipeline

• Existing Buried Structures

• Contamination

• Invasive Plant Species

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Routing of Routing of

Gas Pipeline Gas Pipeline

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Pipeline

Carrington

Power plant site

• 2.4km

• Welded steel

• 600mm dia

• 19.1mm thick

• 70barg

Gas Supply

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1.2km

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Culvert

Culverts

LandfillCanal

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Culvert

Culverts

LandfillCanal

Culverts

Landfill

Canal

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Culvert

Culverts

LandfillCanal

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Horizontal Directional Drill

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CulvertEntry

Horizontal Directional Drill

Exit

Ground Level

Bedrock

30m

Structure

1200m long drill

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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

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Buried Buried

Structures Structures

- Identifying- Identifying

- Removal - Removal

- Mapping - Mapping

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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

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Original Coal Fired Station

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Site Overview

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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

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What we did?

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Foundations more extensive than Desktop Study

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

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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

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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

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Conclusion

Robust Project

Risks mitigated

Fixed price construction contracts

Experience

Lessons Learned

Project Delivery

Methodology

Advance Works

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Thank You

Any Questions?

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