Challenges Presented by
Brownfield 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
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Annual turnover approx €110m
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Projects completed in 115 countries
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Current operations in >20 countries
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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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ESB International - Locations
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ESBI Recent Projects
Dublin Bay Power, Ireland
•412MW CCGT
•Commercial Operation 2002
•Brown Field
Amorebieta, Spain
•755MW CCGT
•Commercial Operation 2005
•Green Field
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ESBI Recent Projects
Coolkeeragh, Northern Ireland
•400MW CCGT
•Commercial Operation 2006
•Brown Field
Marchwood, Southampton UK
•840MW CCGT
•Commercial Operation 2009
•Brown Field
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ESBI Recent Projects
Aghada, Cork, Ireland
•435MW CCGT
•Commercial Operation 2010
•Brown Field
Carrington, Manchester, UK
•860MW CCGT
•NTP 2012
•Brown Field
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Good planning context
Reusing Brownfield Site
Benefits vs
Challenges of
Brown Field
Industrial zoning
Good infrastructure connection
Visual impact
Regeneration
Gas Transmission System
800-1500MW
CCGT
HV Grid
Transport Routes
Residual Site Risks
Cooling
Contamination
Existing services and
structures
Existing Cooling Source
Disruption to existing
Environmental
industrial stakeholders
Reduced Capex
Suitable for CCR/ S
Availability of land
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The Carrington
Project
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Original Coal Fired Station
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Site Overview
WaterS
ource
Gas Supply
HV Substation
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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
Gas Pipeline
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Power plant site
Pipeline
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2.4km
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Welded steel
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600mm dia
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19.1mm thick
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70barg
Carrington
Gas Supply
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1.2km
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Canal
Landfill
Culverts
Culvert
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Canal
Landfill
Culverts
Landfill
Culvert
Canal
Culverts
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Canal
Landfill
Culverts
Culvert
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Horizontal Directional Drill
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Horizontal Directional Drill
Ground Level
Entry
Culvert
Structure
Exit
30m
1200m long drill
Bedrock
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Pipeline Outcome
•Financial Commitment
prior to Financial Close
•Proved viability of pipeline route
•Detailed design available
• Engineering Resource
Requirement
• Extension of Develop
Phase Programme
•Pipeline detailed design
contract
•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
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Buried
Structures
- Identifying
- Removal
- Mapping
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Site Issues
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Existing foundations supported on piles
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Inadequate drawings of foundations
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Very limited information on ground conditions
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Contamination Issues
– Localised hotspots
– Japanese Knotweed
– Asbestos
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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 1
Option 2
Include in EPC Contract
scope
Prep work in advance of
the EPC Contract
Single all inclusive 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
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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
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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
•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
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Conclusion
Experience
Lessons
Learned
Project
Delivery
Methodology
Advance
Works
Robust Project
Risks mitigated
Fixed price construction contracts
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Thank You
Any Questions?
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