“HYBRID” PLANT DESIGN
By:
Paul M. Saville
Vice President
Stellar
[email protected]
21st Annual Campus Energy Conference
Boston, MA
February 2008
Agenda
1. Definition of Hybrid District
Energy Plant
2. Features, Benefits & Design
3. Case Example
4. Summary of Advantages
The “HYBRID” Solution
Hybrid, n. [Lat. hybrida] Genetics. (1) The
offspring of genetically dissimilar parents or stock,
esp. the offspring produced by breeding plants or
animals of different varieties, species, or races. (2)
Something of mixed origin or composition. (3) A
word whose elements are derived from different
languages.
The “HYBRID” Solution
Combining the benefits and features of the traditional
field erected or “stick built” district energy plant with the
latest technology and features of modular plants.
COMBINING THE BENEFITS
“Stick Built” Plants:
Modular Plants:
• Attractive building architecture
• Robust building construction
• Plentiful access areas for equipment
maintenance
• Overhead rail cranes
• Flexibility with layout and desired
employee welfare, maintenance areas
and control rooms.
•
•
•
•
•
•
•
•
Reduced Overall Cost
Guaranteed system performance
Improved Quality
Standard products
Compressed schedule
Pretested
Improved Startup & Commissioning
Better Risk Management
HYBRID PLANT DESIGN
• Majority of the plant system & equipment is
designed, fabricated and tested in 'modular
components' in a manufacturing environment.
VS.
• Prefabricated & tested modules (or skids) are
then shipped to site and installed in the
traditional field constructed plant building.
• This is significantly different than a
normal "construction project" where
the typical district cooling plant and
system is designed and executed
by installing every component in
the field.
HYBRID PLANT DESIGN
• Modular designs are much more reusable and
repeatable from one job to the next than the "stick
built” designs. This facilitates and promotes an
improvement process to the system design and
fabrication much like occurs by the manufacture of
the individual pieces of equipment.
• New plant system efficiencies can be optimized and
improved more reliably because modular designs
are highly analyzed and look much closer at the
interrelationships between the individual
components of the process (chillers, cooling
towers, pumps, piping, valves & controls, electrical
gear, etc.).
CASE EXAMPLE – JLT, DUBAI, UAE
Hybrid Design Anatomy
Architectural
Building
Make-up Water
Storage
Modularized
Plant Room
(specific to UAE)
CASE EXAMPLE – JLT, DUBAI, UAE
Hybrid Design Anatomy
Cooling Towers
Pre-cast columns
Utility Module
Fire Protection
Room
Make-up Water
Storage Tank
Rail Crane
Electrical &
Control Rooms
Chiller Module
• Plentiful access areas for equipment maintenance.
• Complete flexibility to provide any desired employee welfare &
maintenance areas and control rooms.
CASE EXAMPLE – JLT, DUBAI, UAE
Hybrid Design Anatomy
•
•
•
•
•
3D design software is a significant contributor to this evolution.
Pre-engineering occurs to a much greater level of detail.
“Interference checks” performed (mechanical, electrical & structural)
Design errors are minimized.
Allows a large district cooling plant to be treated like a product; and like a product it can
undergo a significant product improvement processes in a very effective and repeatable
manner.
CASE EXAMPLE – JLT, DUBAI, UAE
Hybrid Design Anatomy
Chiller
Modules &
Shipping
CASE EXAMPLE – JLT, DUBAI, UAE
Hybrid Design Anatomy
Utility Module &
Secondary
Pump Module
RESULTS OF HYBRID PLANT DESIGN:
• Less expensive than field erected design and construction.
• Improved system quality as compared to field erected quality.
• Improved safety as compared to field erected construction safety.
• This allows the design and system to retain the benefits of traditional plants:
• Attractive building architecture
• Robust building construction
• Plentiful access areas for equipment maintenance
• Overhead rail cranes
• Flexibility with layout and desired employee welfare, maintenance areas and
control rooms
• Reduced cost
• Guaranteed system performance
• Compressed schedule
• Improved Commissioning
• Better Risk Management
MATCH CAPITAL OUTLAY WITH USAGE:
The modular design allows for flexibility to be integrated into
a phased project implementation plan. Modular construction
allows for the addition of capacity to match the required
demand. In instances when a phased project implementation
plan is changed (i.e. demand is less than or greater than the
total build-out demand), the modular plant allows for the
accommodation of larger/smaller increased in capacity.
CASE EXAMPLE – JLT, DUBAI, UAE
PHASE
PLANT 1
PLANT 2
1
Building + 7,000 TR
Building + 7,000 TR
2
3
PLANT 3
Building + 7,000 TR
7,000 TR
4
7,000 TR
7,000 TR
7,000 TR
5
14,000 TR
7,000 TR
7,000 TR
6
7,000 TR
7,000 TR
14,000 TR
TOTAL DESIGN
BUILDOUT
35,000 TR
35,000 TR
35,000 TR
Changed after award to: 35,000 TR
105,000 TR
42 ,000 TR
28,000 TR
CASE EXAMPLE – JLT, DUBAI, UAE
• Modules delivered to jobsite
• Building designed to accept
module installation
CASE EXAMPLE – JLT, DUBAI, UAE
• Modules inserted into building
• Modules prepared to be
installed via gantry crane
CASE EXAMPLE – JLT, DUBAI, UAE
• Module set in final location
• Module rigged into place
CASE EXAMPLE – JLT, DUBAI, UAE
• Module interconnecting piping
and wiring reconnected
CASE EXAMPLE – JLT, DUBAI, UAE
• Because each module in the plant has it’s required infrastructure built into the
skid (pumping, MCC’s, controls, etc), the capital associated with each phase is
spent when the load is added to the system.
• Skidding of equipment
eliminates the need for
concrete house keeping pads
• Modules connected to
prefabricated system headers
• View from level of overhead
rail cranes
CASE EXAMPLE – JLT, DUBAI, UAE
• Putting the modular system components inside a traditional well designed
building eliminates the disadvantages of a “pure” module solution where the
module is inside an enclosure (and tight access and limited facilities are
created), yet it retains all the benefits of the modular solutions
CASE EXAMPLE – JLT, DUBAI, UAE
• Attractive building
architecture
• Robust building
construction
• All the benefits of a
Modular system
SUMMARY OF ADVANTAGES
Key Customer Benefits
Cost Effective – Less than traditional field erected plants.
Flexible – Closely match plant capacity with customer demand.
Efficient – Equal or better efficiency than traditional field erected plants.
Reliable – Quality controlled fabrication based upon proven technology.
Durable – Designed to last as long as traditional field erected plants.
Time Compressed – Can be completed in less time than field erected plants.
Optimized - can be treated like a product; and like a product it can undergo a
significant product improvement processes in a very effective and repeatable
manner.
SUMMARY OF ADVANTAGES
Reduced Overall Cost
Reduced Engineering Cost – Pre-engineered and standard designs create engineering
and fabrication labor efficiencies (its been done before) and allows for closer estimate of
cost of fabrication.
Increased Productivity – Field component of project cost is reduced due to the
replacement of field labor tasks in shop environment which are done more efficiently with
personnel who are well trained and have constructed similar modules previously (no
learning curve).
Reduced Field Cost – Field labor skill requirement is reduced due to scope complication
reduction. Lower specialty contracting requirement results in lower labor costs in the field.
Reduced Contingency Cost – Well defined project scope and pre-engineered scope
reduces the opportunity for scope creep and the associated cost creep and change
orders.
Reduced phasing costs – The Hybrid design lends itself better to reducing and delaying
capital expenditures on infrastructure for future phases.
SUMMARY OF ADVANTAGES
Improved Quality
Controlled Environment – Modules are
constructed in a controlled environment that is
not affected by weather. This allows for a
consistently productive work environment that
results in very efficient fabrication of the
modules.
Comprehensive Quality Plan – A quality
assurance plan is more easily implemented in
a fabrication facility due to the proximity and
availability of in-house quality control
inspectors.
Inspection and Testing – Modules can be
tested prior to leaving the fabrication facility. If
there is a corrective action required it can be
done in the fabrication facility prior to shipment
utilizing trained personnel. Modules undergo
hydrotesting, controls loop check and controls
simulation, electrical continuity check and
megger testing prior to shipment.
SUMMARY OF ADVANTAGES
Compressed Schedule
Reduced Engineering Time – The pre-engineering
associated with modular designs allows for a shorter
engineering and design cycle. This can also allow for
quick turnaround of drawings, submittals and
specifications. The pre-engineering also expedites the
design schedules for civil and structural disciplines as the
related MEP information is available sooner.
Early Mechanical & Electrical Start – The process
mechanical and electrical work is constructed in a
fabrication facility much sooner than it would be in a stick
built plant. It is actually fabricated in parallel with the site
civil, structural and architectural work as apposed to in
series.
Early Mechanical & Electrical Completion – the M&E
site work is significantly reduced due to the fabrication of
the modules offsite. In addition, system startup and
commissioning time is cut in half due to the pretesting
that is completed at the fabrication facility.
SUMMARY OF ADVANTAGES
Better Risk Management
Quality Risk – Shop fabrication reduces quality risk by following a strict and consistent
quality assurance program. Field implementation quality programs do not generally
include as in depth of a quality assurance program.
Performance Risk – “Total system” performance of pre-packaged modules can be
guaranteed more readily and reliably by the provider as apposed to performance
guarantees of individual pieces of equipment and suppliers.
Labor Risk – Skilled labor is concentrated in the fabrication facility where workers have
more consistent training and skills to complete the tasks associated with the construction
of the modules. Automatic welding equipment and material handling is built into the
production of the modules, allowing for higher labor productivity.
Scheduling Risk - The process M&E work is constructed in parallel with the site civil,
structural and architectural work as apposed to in series making one less dependent on
the other. Weather related delays are reduced due to the prefabrication of the modules in
a weather controlled fabrication facility.
Contractor Risk – Contractor risk is reduced due to reduced
technical expertise of required field scope. Most scope with
specialty skill requirements is performed in the fabrication
facility.
QUESTIONS