Project Execution Plan.pdf

Doha

Beirut

Cairo

London

ENGINEERING, PROCUREMENT, CONSTRUCTION, TURNKEY CONTRACT FOR THE INTEGRATED DISTRICT COOLING PLANT AT THE PEARL PROJECT DOHA - QATAR

PROJECT EXECUTION PLAN Q06024-IDCP-PLN-GT-001-REV A

C.A.T. INTERNATIONAL QATAR W.L.L.

Q06024-IDCP-PLN-GT-001-REV A

INDEX Preface scope of works 1. Execution statement 2. Interpretations and Abbreviations 3. Project Execution Plan 3.1 C.A.T. Approach Plan 3.2 Long Lead Items Procurement 3.3 Bulk Material Procurement 3.4 Construction Activities 3.4.1. Temporary Facilities 3.4.2. Organization Chart 3.4.3. Subcontractors 3.4.4. Field Coordination Procedures 3.4.5. Detailed Construction Schedule 4. Detailed Construction Schedule 4.1. Data Collection 4.2. Engineering and Design 4.3. Construction of the Cooling Plant 4.4. Construction of HEX Buildings and ETS’s 4.5. Calibration 4.6. Testing and Pre‐commissioning 4.7. Commissioning 4.8. Training 5. Quality Assurance (QA) 6. Health ,Safety and Environment (HSE)

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Appendix 1‐ PROJECT CHART Appendix 2‐ ORGANIZATION CHART Appendix 3‐ LONG LEAD ITEMS LIST Appendix 4‐ PROJECT KEY MILESTONES Appendix 5‐ TEMPORARY FACILITIES Appendix 6‐ LIST OF SUB‐CONTRACTORS Appendix 7‐ CIVIL METHOD STATEMENT LIST Appendix 8‐ MECHANICAL METHOD STATEMENT LIST Appendix 9‐ E & I METHOD STATEMENT LIST Appendix 10‐ DESIGN INTENT REPORT

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1. Execution statement For proper execution and timely completion of the project, we are planning to follow our proposed project execution plan, which is in line and conforms to the target scope of work and completion dates as stipulated in the contract documents.

2. Interpretations and Abbreviations In the project execution plan, the following words and expressions shall have the meaning hereby assigned to them, except if other specified or where the context other wise requires: EMPLOYER (or Client, Owner, Company) means QATAR COOL ‐ QC will be commonly used instead of QATAR COOL. PMC means DAR AL‐HANDASAH – DAR will be commonly used instead of DAR AL‐ HANDASAH. CONTRACTOR means C.A.T. INTERNATIONAL QATAR W.L.L – C.A.T. will be commonly used instead of C.A.T. INTERNATIONAL QATAR W.L.L. DESIGN TEAM means STANLEY Engineering ‐ SCI will be commonly used instead of STANLEY Engineering.

3. Project Execution Plan 3.1. C.A.T. Approach The implementation of this project Execution Plan that complies with Q.C requirements will be the main objective of C.A.T. C.A.T. will be working with EMPLOYER (QC) personnel and PMC (DAR) personnel, and Design Team (SCI) personnel to ensure that this principal objective is accomplished. Our experience on similar projects has seasoned our personnel to complete any and all services required with optimum performance results. The C.A.T. Projects Team and senior management are committed to providing a project that meets EMPLOYER’s objectives as well as our own principal objectives. We take pride in our work and are confident these will be accomplished. The principle objectives that the C.A.T. management expects to be met are as follows: − Meet all critical milestones and complete the Project on schedule -3-


− Maintain project costs within budget − Meet technical performance objectives − Obtain total satisfaction from EMPLOYER The proposed Project Chart (see Appendix 1) has been developed to achieve the above mentioned expectations. The successful management of the project requires good communications between the engineering team and construction team, comprehensive management information systems and a competent, well‐directed project team. Directly upon award, a qualified management and supervisory Project Team was appointed to prepare a detailed study of the project requirements as far as engineering, materials, equipment and labor force required (see Appendix 2, Contractor Organization Chart). This group of dedicated project personnel began identifying the priorities to be completed in the early stages of the project and planned for the initial “kick‐off” meeting that was held in QC offices. This initial meeting was important in establishing a strong team relationship with the QC, DAR & SCI. After award of the contract, the management personnel from areas began mobilizing to fulfill the staffing needed for the project .This staff started with SCI verifying the available design. Based on the concept design, procurement of the LLI Long lead items (see list in Appendix 3) started as per the procurement procedures. The project key mile stones (see Appendix 4) were to be confirmed as per the suppliers & project progress. SCI started with the concept design, aiming to submit the same to QC & DAR for clearance and to go ahead with the detailed design. -4-


3.2. Long Lead Items Procurement FLOW OF PROCUREMENT ACTIVITIES

Composite Vendor List

Concept Design

Commercial Terms

Requisition

Procurement Policy and Procedures

Project Vendor List

Inquiry

Bid Analysis and Tabulation Technical / Commercial

Material Status Report

Client Approval

Negotiation with Vendor

Purchase Order Award

Expediting and Shop Inspection

Data Input

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Traffic Operations

Arrival at Site


The requisition of LLI is critical and will be developed on a rush basis, immediately after contract award and approval of concept design. Owning to the critical milestones requirements, it is essential that acceleration “premiums” for specific equipment and materials to be developed and reflected C.A.T.’s flow procurement activities, as shown above, include the following polices: ‐ A well‐screened project vendor list with a preference for QC recommended vendors will be prepared , reflecting C.A.T. recent procurement experience; due consideration is given not only to technical capabilities , commercial competitiveness and offered guarantee conditions, but also to delivery performance. ‐ Purchase order placement will be based on quotation development except where source or lead time constraints dictate otherwise. ‐ Fast‐ tracking procedures are established to facilitate early procurement of long lead time items; closely‐knit inter facing among QC, DAR, C.A.T. and SCI is expected and will be implemented. ‐ Rigorous expediting and frequent tracking of materials status will be performed in the realization that any delay from the Construction Required Dates (CRD) of materials arrival on the site will endanger meeting of the contractual project completion date. ‐ An efficient field materials control system will be established and through indoctrination on warehousing operation will be carried out. LLI procurement will be done as per our C.A.T. standard procurement procedure, in order to comply with the employer specified policies. 3rd Party Validation (if required) for LLI procedure will be performed as and when required. As part of procurement activity C.A.T. & SCI will carry out a technical evaluation for each item starting with technical clarification and finalizing with a Technical Evaluation Report C.A.T. & SCI will carry out also a review of vendors drawings / documentation as part of the above mentioned procurement activity. The technical bid evaluation will be undertaken by each engineering discipline. The technical bid evaluation is used to summarize the technical aspects of bids received for a specific requisition, in order that the bids may be compared and evaluated. Proposals (bids) are forwarded to the SCI Engineers and CAT Construction Managers for evaluation. A thorough review of technical data will be made to determine whether bids conform to the specified technical requirements. Any deviations or inadequate information is identified at that time. In addition, C.A.T & SCI coordinate any other reviews applicable to the particular evaluation (construction impacts, technical specialist review, etc.) and incorporate the results of these reviews on the technical bid evaluation. The technical bid evaluation is then reviewed and approved by the Project Manager. At this point, C.A.T. area procurement department shall evaluate the bids based on project requirements and -6-


commercial issues. Compliance with project requirements will be imposed on the vendor for all aspects of his equipment. Once a bid is determined to be technically acceptable and commercially optimal, C.A.T. will send its recommendation to DAR for approval. C.A.T. will award purchase orders only upon obtaining QC/DAR approvals. Upon receiving Company’s vendor approvals, C.A.T. will issue purchase orders to the selected vendors. All purchase orders are monitored. Suppliers will submit monthly progress reports to track the equipment status. Similarly, the shop drawings/production and delivery schedule report will depict, in details, the status of vendor drawings, data, factory acceptance tests and inspections, other relevant documents as requested. All LLI will be received on site. All LLI will be checked upon receipt for quality, quantity, conformance with specifications, damage and tag or identification number, and entered on stock cards. A receipt report and, if applicable, an overage, shortage or damage report will be prepared. Issue will be made on a materials requisition form signed by a signatory from a limited list of persons authorized by the project manager. The project procurement officer will oversee all locally supplied material. Receiving, warehousing, reporting and materiel issued for construction activities shall follow C.A.T. QA/QC procedures. Imported items will be received by purchase order number/tag number if appropriate, and checked for quantity and evidence of any shipment damage. Contractor will establish a construction warehouse system, which include covered and open storage to control the material until it is needed for construction. The Construction Manager will be responsible for issuing material transfer authorizations to release materials to the various Construction Superintendents. The Procurement Officer will be responsible for providing marking and tagging instructions on all purchase orders. This effort will provide means in the identification of all materials received and establish traceability as required. As project LLI are received, a report of materials received will be transmitted to update the records and generate reports for construction management and QC use. Material inventories will be adjusted as contractor issues materials and equipment for construction through standard material transfer document. The procurement team will interface with the quality control function to ensure that materials and equipment are acquired without disrupting the design and construction schedules. Given the high coordination demands of this function, the Project Procurement Officer will serve as a key facilitator between the various elements of timely procurement. He will track the progress of materials and

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equipment through delivery to the work site, providing a centralized point of information for all project management. The project quality and project controls functions will supplement the procurement effort in support roles. Inherently linked by their common goals of vendor quality and schedule impact, these two functions will closely interface with Procurement throughout the life of the project. The quality control function monitors the procurement function with each of its supporting positions. Working to ensure quality from both its subcontractors and vendors, this function assumes the role of quality assurance for its vendors and quality control for the entire project through continued analysis of our efforts as well as our vendors and subcontractors. Where discrepancies are observed, non‐conformance reports will be prepared and submitted. Provision has been made for FAT tested and witnessed by QC and C.A.T. The QA/QC Manager will verify the technical viability of potential vendors and subcontractors. Through a documented process and inspection, this coordinator will research the above criteria as well as the quality systems of potential suppliers. The project Planning Engineer will predominantly assist in the scheduling and document control activities. Working with the Expediter on the area Procurement Department, the project Planning Engineer will develop procurement schedules, linking the relationship between procurement of specific equipment and materials with critical design and construction activities. The Document Controller will maintain the officials vendor data control register, updating and tracking all vendor data processed for review/approval. The Document Controller will coordinate vendor communications, receiving and returning marked‐up and/or approved drawings or other vendor data. This data will include, but is not limited to, design calculations, parts lists, special tools, spare parts recommended by the vendor and various sub‐vendor documents. Vendor data submissions will include drawings, spare parts data packages, operating and maintenance manuals/instructions, procedures, and other pertinent data needed to support the equipment or material being purchased. On arrival of products to storage area, the storekeeper with the help of relative department (Mechanical, Electrical, etc) or his designate shall start unloading, checking against the purchase order or the loading note and labeling each item with its correct description, tally sheet number, stock number, drawing number, and store it in its proper place as advised by the specifications. Upon receipt of equipment, each delivery shall be checked for quantity and quality, shortages visible or concealed damages. Should there be any damages, shortages, etc then the Site Management shall be informed according to applicable procedure. The material received shall be recorded on stock records as per the applicable procedure. -8-


To avoid double handling and only in the event that it suits, lifts will be initially programmed to arrive to site after their prospective foundations are ready. The QA/QC Department and the storekeeper shall ensure that the handling of products is according to vendor specifications, contractual documents, safety standards and project requirements. Similarly, he shall ensure that concerned people are properly and currently informed of material received or to be received. All concerned employed in material handling shall be well conversant with various projects and have had previous experience dealing with construction permanent material. Special considerations shall be applied to materials and components that should not have unnecessary handling due to weight, or configuration. 3.3. Bulk Material Procurement The materials procurement, other than LLI, will be done as per the same described procedure for LLI. 3.4. Construction Activities Soon after N.T.C. a construction group was organized within the Project Team. Based on the construction strategy established and project requirements identified during the bidding stage, this group will develop the Construction Plan, keeping in close contact with the engineering and procurement groups. The Construction Plan will be continually revised and updated as required to reflect the latest information affecting construction operations and will cover the following areas: ‐ 3.4.1. Temporary Facilities ‐ 3.4.2. Organization Charts ‐ 3.4.3. Subcontractors ‐ 3.4.4. Field Coordination Procedures ‐ 3.4.5. Detailed Construction Schedule 3.4.1. Temporary Facilities Temporary facilities (see Appendix 5) shall be erected in close proximity to the works, after securing M/S UDC’s & DAR’s approval to the layout and locations of site offices, stores, workshops, etc... Site Plot Plan and offices Areas shall be fenced in accordance with the Construction Regulations. We shall accommodate our personnel in existing camp in Rayyan & Shahaniyah Areas. Proper transport shall be provided to ensure the transfer of employees from and to site in comfortable and suitable conditions .Staff will be accommodated in furnished apartments. QC & DAR requirements for Temporary Facilities shall be completed in accordance with the supplemental terms and specifications. Safety and Environmental Protection shall be maintained by our Safety department as per Requirements and as per CAT Safety Manual.

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Our HSE Department personnel are as well familiar with the handling and securing passes from the local authorities and UDC; immediately, the process of securing passes to all personnel entering the zone shall proceed to guarantee that such passes will be available on time. 3.4.2. Organization Charts The Project Chart (see Appendix 1) and the Contractor Chart (see Appendix 2) have been structured to effectively and economically achieve the project construction objectives. The proposed organization addresses all the project trade requirements as far as management and supervision. It is designed in a way to provide QC & DAR with a comprehensive and homogeneous team effective in the execution of this type of works and meeting the project milestones. Staff C.V’s, from Supervisor level and above, shall be submitted to QC & DAR for prior approval. 3.4.3. Subcontractors The subcontractors (see Appendix 6. List of Subcontractors) shall cover specific areas and shall be specialized for their expertise area. Prior approval will be obtained from DAR before subcontracting the work. The Project Manager, Construction Managers, Project Engineers, Discipline Engineers, QC and Safety Engineer shall control the Subcontractor’s field of activities. 3.4.4. Field Coordination Procedures Field control will be broken down into the following areas, with management coordinating the separate efforts into an effective and efficient field organization: ‐Manpower Control ‐Safety and Security Control ‐Warehousing and Materials Management Plan ‐Construction Equipment Control ‐Field Changes Control ‐Document Control 3.4.5. Detailed Construction Schedule The detailed Construction Schedule is covering: ‐Data Collection ‐Engineering and Design ‐Construction of Cooling Plant ‐Construction of HEX buildings and ETS’s ‐Calibration ‐Testing and Pre‐commissioning ‐Commissioning ‐Training ‐Warranty Period - 10 -


The construction schedule is detailed in next chapter.

4.

Detailed Construction Schedule

4.1 Data Collection C.A.T. & SCI will prepare the checklists to identify the information needed and the information to be obtained from DAR and other parties. The data collection activities embrace each of the various disciplines and will be structured to meet the needs for the design. Critical to the schedule for this project is the data site survey that will be undertaken by C.A.T. at the start of the project. 4.2. Engineering and Design SCI will review the project requirements with QC, DAR & C.A.T. to confirm and obtain all required data pertaining to the project deliverables. During the meetings, the main equipments and systems will be finalized. Data, such as production rates, physical properties of the products and other relevant data will be reviewed and agreed. SCI will develop the concept design, pass it to CAT for double checking and reviewing it, and verify it with QC/DAR prior to developing the design. A Design Intent Report will be issued, (Appendix no. 10). Based on the verified design, the procurement of the LLI‐Long Lead Items will start as per the procurement procedures already described. The exact sequence of activities during the engineering and design phase will be dependent on the schedule requirements for construction and consequently the manufacturing and shipping times for procurement. Thus, some activities may need to start earlier based on the information provided by QC in the stage prior to award. SCI will perform detailed design ensuring that all process related activities defined in the project requirements will be undertaken in accordance with international and QC standards and codes. SCI’s experience of similar projects will enable a recognized and effective design. Once the detailed design is substantially completed and approved, the mechanical, instrumentation and electrical designs will commence and the finalized specifications and requisitions completed. Following QC/DAR approval, the material and equipment will be tendered and purchased. Using the data obtained during the surveys and the finalized process drawings, the plot plans and layout drawings will be developed for DAR approval.

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The piping drawings and specifications will commence, based upon the approved plot plan and layout drawings. These will be completed once finalized vendor data is received and approved. Where applicable SCI/C.A.T. will check for compact designs with simplicity of installation but which retain ease of access for operation and maintenance. SCI/C.A.T. will ensure that the plant piping is laid out in an economical and effective manner to suit the process and operability requirements. SCI/C.A.T. will ensure that all civil engineering will be detailed with due regard to the local conditions and taking into account the specificity of the area. SCI/C.A.T. will also ensure that full consideration will be given to operational functionality, safety and aesthetic considerations. Based upon the equipment & piping arrangements and relevant approved vendor data the mechanical, electrical and instrumentation drawings will be completed and final MTO’s established. When drawings are finalized and approved by QC/DAR they will be issued as Approved for Construction (AFC). The construction of the whole project will be performed according to our proposed construction schedule that gives the start and finish date of each activity. 4.3. Construction of the Cooling Plant The works for the plant and administration building shall cover but shall not be limited to the following: ‐ Site clearing ‐ Excavation and compaction ‐ De watering ‐ Water Proofing ‐ Raft foundation & Building Concrete Works ‐ Precast Concrete Works ‐ Equipment foundations ‐ Finishing Works ‐ Equipment Works ‐ Piping Works ‐ Fabrication & Erection ‐ Electrical & Instrumentation works ‐ Landscape, Roads, curbstone and sidewalks Site Clearing We shall carry on all the necessary clearing, grubbing and soft landscaping in accordance with the specifications .Excavated material shall be removed from the site and replaced by suitable one if required, all as specified .We confirm that such works shall start after site possession and securing the related approval and permits and agreeing to the levels. Site clearing will be performed partially by C.A.T. and mainly by our excavation Sub Contractor. - 12 -


Excavation for Foundation and Substructures The building shall be divided into 4 Areas. Areas are separated by construction joints. Each area might have a different excavation level. These levels will be calculated by SCI and agreed by DAR. The excavation work shall be executed, by our Subcontractor and under our supervision, in accordance with drawings, specifications and instructions. Thus, excavation shall be done to the lines and grades or elevation, agreed with QC & DAR during concept Design evaluation and cleared with UDC. Excavated material shall be used for backfilling providing it passes required tests. Unsuitable material shall be removed when encountered and replaced by suitable one. Permanent works blinding concrete membrane or such other protection as specified on the drawings shall be placed, by our concrete subcontractor, following completion of excavation and compaction works, clearing the soil tests with DAR and as soon as it is practical .All precedent works is to be executed to DAR satisfaction. Dewatering Dewatering shall be done via submersible pumps in wells distributed around the perimeter of the excavation. Water will be pumped to the near by sea. The pumps shall be fed from two Electrical sources for redundancy. Dewatering shall be subcontracted to a Professional Specialist. Water Proofing Waterproofing shall be done by a Professional Specialist subcontractor using Material approved by DAR. The water proofing activities are mainly in the Foundation stage, wherever the concrete touches surrounding soil and on the roof where we have the Cooling Towers. Raft Foundations & Building Concrete works The building shall be divided into 4 Areas. Areas are separated by construction joints and therefore can follow different schedule of works once they reach the superstructure levels. Concrete works shall be executed by an approved Concrete Subcontractor. For civil method statement list, refer to Appendix 7 A QA/QC procedure covering all the activities related to the concrete works shall be submitted to DAR for approval. The latter provide for all the sampling and testing activities carried out in the field and/or in the laboratory. Sources of material i.e. suppliers/manufacturers and material to be used shall be in prior approved by DAR including working methods and delivery conditions. Transport, transport means, protection, delivery, storage and certification of cement shall be done in accordance with specifications and approved procedures and to the satisfaction of DAR. A bar bending schedule shall be submitted to DAR for approval. The number, size, form and position of all steel reinforcing bars, ties, links, stirrups and other parts of the reinforcement are to be in accordance with the drawings and kept in the correct position in the forms without displacement during the process of vibrating, tamping and ramming the concrete in place. The approved spacers shall be used during the process. The concrete cover shall not exceed tolerance unless particularly otherwise specified. - 13 -


During the previously detailed activities, inspection and tests shall be conducted as required in the specifications and to DAR satisfaction. Records shall be generated, maintained and kept for all the duration of the process. Concrete shall be placed in the positions and sequences indicated on the drawings or in the specifications. Raft foundations shall be constructed first, after watering proofing and screeding works is done. Different Rafts sizes will be constructed for different areas. Sizes will be calculated depending on loads in various floors and equipment vibrations. Method statements shall be submitted for large pouring areas. Backfilling will be made on top of the raft foundations to bring the construction to the required levels, prior to proceeding with the different floor plans. Two large Tower cranes will be erected to cover most of the building area and adjacent steel workshop. Mobile cranes will be used to cover the minor areas unreachable by Tower Cranes. The work sequence will follow our schedule of works in order to match the delivery and installation schedule of main equipment. Civil crews shall be allocated to Foundations, Structures, and other crews to Buildings. The crews shall be scheduled in accordance with the Construction Program. Concrete specified in the documents shall be obtained from approved batching plants. For workability and protection of concrete, admixtures shall be used, if needed. For all concrete works, ordinary or Medium Sulfate Portland cement shall be used. Concrete surfaces adjacent to soil shall be covered by bituminous paint. Slump control shall be executed and samples shall be taken for strength control during the placing of concrete. Concrete will be compacted with the use of a vibrator. Afterwards, the necessary curing will be done. Foundation, column and concrete wall Formwork shall be made of conventional wooden or steel formwork. Formworks shall be prepared for concrete placing after the control of axes, elevation, alignment and the necessary strengthening have been carried out. All formwork systems shall be strengthened by scaffoldings and working platforms. The client/PMC shall approve the completed works. Precast Concrete works Precast hollow core panels and beams will be subcontracted to a specialist company, following approval by DAR. This company shall supply and erect the precast items with the assistance of the Concrete Subcontractors and CAT. Some of the works will be erected by the large Tower Cranes and the rest with long reach, properly sized Mobile Cranes Concrete works shall be executed by an approved Concrete Subcontractor. - 14 -


A QA/QC procedure covering all the activities related to the precast concrete works shall be submitted to DAR for approval. Equipment Foundations Once Material is approved and shop drawings produced and approved, Major Equipment foundations shall be designed, coordinated with concrete works and constructed on site in accordance with Manufacturer recommendations. Finishing Works All Sundry and finishing works shall be executed by C.A.T and by different approved Subcontractors in accordance with approved finishing schedules and Material. Selection of Finishing Material will be based on the requirements of the Acoustic Study that caters for the noise requirement of the Project and with the Aesthetic requirements of the specifications detailed in our Alternative No. 2. Equipment Works Once the major Equipment and Material are approved, manufacturer shop drawings will be coordinated and integrated into the Shop Drawings. C.A.T. shall also prepare the necessary procedures /method statements for the mechanical material and equipment installation, prior to any Installation. (See Appendix 8 for Mechanical Method Statement list). For the major equipments to be erected by C.A.T. the work is to be executed under the direct supervision of the supplier representative when required and in accordance with provided instructions and manuals. All necessary measures shall be taken to protect and preserve the supplied equipment. C.A.T shall execute the works with all necessary safety and security precautions. Having the concrete foundations properly cured, brush‐hammered and shimmed to the right elevation, the chillers, RO equipment, and other mechanical equipment shall be installed as per approved method statements on the respective foundations leveled and properly centered. For pumps, preliminary alignment shall be carried out before grouting. All equipment shall be installed as per QC/DAR requirements and vendor’s specifications and recommendations. Special Platform on rail/track system will be manufactured in our workshop to bring the chillers, pumps and other equipment into the building and right to the location where they should be installed. Hydraulic jacks, telehandlers and special tools will be used to maneuver inside the plant building. Equipment on the first floor can be brought in via external platforms with the help of a crane or from the inside in the ground floor with the use of electrical hoists. Equipment on the roof will be installed using the tower cranes or telescopic external mobile cranes. Cooling Towers shall - 15 -


be assembled by the manufacturer. All Major Equipment shall be started, tested and commissioned by the manufacturers. Piping Works Shop Drawings for piping fabrication and erection will be prepared and utilized in the fabrication shop for preparing spools, ready to be erected. All works shall be carried out in line with above. Piping erection shall commence when building is ready. Fabrication and Erection Pipe fabrication work shall start in the fabrication shop in the designated area on site. An N.D.T. subcontractor will be carrying out the required N.D.T. for C.S. welds as per specifications done in the fabrication shop so that any repairs are carried out before transporting the spools to site. Prior to fabrication, field checks shall be carried out to ensure that the shop drawings are compatible with the site conditions. Copies of the shop drawings used by the fabrication crews shall be given to the erection crews. These copies shall show the numbers assigned to the welding joints and shall indicate which joints were already tested in the fabrication shop. This shall enable the site crews to correctly identify and mark the welds performed on site. This shall ensure proper reporting and assist the N.D.T. crews/QC Inspectors to attend and control all the field welds. The QA/QC officer along with the foreman responsible for the fabrication will ensure that all welds on the drawings are clearly marked to distinguish the fabrication welds from the field welds. A record of every day welds and N.D.T. will kept. Once fabrication, welding of the spools are complete, the spools shall be transported to site for erection. All the spools to be tagged properly prior to transportation to site. All erection works shall be in accordance with the drawings and specifications. The fabricated spools shall be transported to their designated area one day ahead of the start of erection to avoid any congestion in the existing facilities. Once the spools belonging to the system are all erected, connected to the rest of erected pipes and checked, the system will be punched out by us to ensure that installation was carried out as per the drawings, field supports are all in position. Once satisfied, all relevant paper work will be submitted to DAR and a request to start hydrostatic testing will be put in. - 16 -


Electrical & Instrumentation Works Upon design approval and in accordance with material specifications, manufacturer and supplier will be submitted to Client for approval, orders will be placed upon suppliers and weekly status reports will be requested to ensure timely delivery to site. Transformers, switchboards, light fixtures and flood lights will all be installed as per manufacturer’s recommendations. Vendor’s representatives will conduct the commissioning of the switchgears and the transformers. (See Appendix 9 for Electrical Method Statement list). All Electrical Switchgears and MCC’s will be delivered in sections and assembled on site by C.A.T. except for the 3.3 KV Switchgears and Soft Starters which shall be assembled by the Manufacturer/Supplier. Supervision of installation, checking of Bus Bars jointing, Testing and Commissioning will be performed by the manufacturer. All Transformers will be delivered and installed on site by C.A.T. Supervision of installation, Testing and Commissioning will be performed by the manufacturer. All raceways, cables, lighting, electrical accessories, lo current systems will be delivered and installed on site by C.A.T. Cable terminations will be made by C.A.T. except for 11 KV cables which shall be made by approved and licensed subcontractor. Supervision of installation, Testing and Commissioning of Lo Current systems will be performed by the Suppliers. All electrical cables shall be laid according to the cable schedules and adhering to the following steps: Prior to cable installation, a cable cutting schedule detailing the cable number, type, size, length, and cable drum number shall be established to avoid and minimize any wastage as much as possible. The said schedules shall be based on the following data: ‐ Actual individual cable length. ‐ Cable length on the drum ‐ Place on installation to minimize double handling Cable drums shall be transported to their respective site. Actual length of the cable shall be measured on site and a record of each cable number type and length shall be made. All distribution boards (lighting, small power), Push button Control station, and marshalling box will be connected in accordance with Electrical Installation Specification, attached schedules and

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drawings. All lightning and grounding shall be done as per specification and with relevance to the applicable drawings. Electrical systems will be tested as per relevant test procedures that will be submitted during the course of the project. Instrumentation and control will be subcontracted to a nominated subcontractor and system integrator. Instrumentation and Control Subcontractor will install all Controls and Instrumentation as per his approved Method Statement. He shall also install and terminate the instrument cables as per C.A.T. Method Statement. Absolutely no pre‐commissioning shall start until the grounding system is completed and tested. Landscape, Roads, Curbstone and Sidewalks Works Once the building is erected and main Equipment installed and the need for large mobile cranes is over, the above work shall start, noting that the final area to be landscaped is subject to QC/UDC approval. 4.4 Construction of the HEX Building & ETS ’s Construction of all Heat Exchangers buildings and ETS’s will be similar to methodology to the once of the plant. Close coordination will be made with other contractors, via DAR, in order to possess sites of HEX’s and to coordinate works for ETS’s. 4.5 Calibration Qualified technicians will be utilized to carry out the calibration of the instruments. Records documenting the calibration will be kept in our Document Control Department. All instruments used for calibration shall be certified by a Third party. A team shall be assigned to remove the skid‐ mounted instruments and their re‐installation along with the field instruments. Dedicated instrument fitters will be responsible for the installation of the tubing on site under the supervision of the instrument and instrument supervisor. The fitters will proceed with the testing of the tubing after completion the installation. After complete installation of the tubing, instruments, instrument cables and all required testing, loop checking shall start according to loop sheets previously prepared by the instrument engineer and approved by the Client. - 18 -


4.6 Testing and Pre‐Commissioning Upon the completion of construction of an individual system, a testing / pre‐commissioning crew shall be assigned to carry out the final inspection before offering the system to the Employer for final inspection. This crew shall be responsible: ‐ Ensuring that the installation was carried out as per the project’s specifications. ‐ Make certain that all the required testing had been carried out successfully. ‐ Confirm that all the related documentation is in order During the construction phase the QA/QC engineer along with the discipline engineers shall be responsible for maintaining the quality and ensuring that the supervisors are carrying out the installation as per the drawings and specifications. The inspection facilities utilized on this project shall include: ‐ Hydrostatic testing A schedule shall be made and submitted to the client approval. This schedule shall indicate the date and the location in the field of the proposed hydro test. Pipe flushing and cleaning to be included. ‐ Loop Checking The loop sheets shall be prepared and submitted to the client for approval. A schedule of loop checking shall be made and agreed with the client to avoid any disruptions and ensure the smooth continuity of work. ‐ Testing and inspection procedures Detailed testing and inspection procedures shall be prepared at the beginning of the project. These procedures shall cover all the aspects of the works and be implemented throughout the execution of the project. On every successful test completion, results shall be transcribed onto formats, copies of which shall be submitted to the company for their records. 4.7 Commissioning C.A.T. is considering employing a subcontractor for the Testing and commissioning activities. This subcontractor shall check the design drawings at the design stage. Commissioning will be performed following on approved Method Statement which shall be submitted during the course of the project providing electricity and other services are available. 4.8 Training C.A.T. through its subcontractors and suppliers will provide training services for QC personnel as specified in our proposal. The training program will be set up for managers, supervisors, operators and maintenance personnel.

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A full program will be developed in detail and in close cooperation with QC. Such a service is considered one of the most important steps for a successful execution of the project including commissioning and maintenance. The foreseen Training Aids are but not limited to: ‐ Training Manual, prepared for this specific purpose. ‐ Operation Manual. ‐ Maintenance Manual. ‐ Safety Manual.

5.

Quality Assurance (QA)

We confirm that all QC requirements and recommendations shall be adhered to and put into application. The QA Plan for IDCP has been issued to meet the Employer and C.A.T. QA system requirements.

6.

Health, Safety and Environment (HSE)

C.A.T. ensures that all construction employees are aware of and adhere to all safety rules and regulations. C.A.T. ensures the promotion of safety, health, and environment protection as a mutual objective for management and employees at all levels, including subcontractors. We will give detailed safety and security instructions to each subcontractor prior to the commencement of work and during the construction period. We confirm that all QC requirements and recommendations shall be adhered to and put into application. The HSE Plan for IDCP has been issued to meet the Employer and C.A.T. requirements. List of Appendixes: Appendix 1 – PROJECT CHART Appendix 2 – ORGANIZATION CHART Appendix 3 – LONG LEAD ITEMS LIST Appendix 4 – PROJECT KEY MILESTONE Appendix 5 – TEMPORARY FACILITIES Appendix 6 – LIST OF SUBCONTRACTORS Appendix 7 – CIVIL METHOD STATEMENT LIST Appendix 8 – MECHANICAL METHOD STATEMENT LIST Appendix 9 – E & I METHOD STATEMENT LIST Appendix 10 – DESIGN INTENT REPORT

- 20 -

APPENDIX 1 PROJECT CHART RELATIONS: FORMAL AUTHORITY / COMMUNICATIONS / REPORTING COORDINATION LIMITED AUTHORITY

EMPLOYER QATAR COOL

CONTRACTOR C.A.T. INTERNATIONAL QATAR W.L.L

DESIGN TEAM PMC DAR AL HANDASAH

STANLEY CONSULTANTS INC.

APPENDIX 2 ORGANIZATION CHART

Qatar Cool N.El- Saadi

C.A.T. H.O C.O.O M. El Hajjar

PMC - DAR K. Salman

Qatar Area Manager M. Matar

Project Manager Nazih Ghazi

Expedition / IT Admin R. Geryes

Project Coord. Mohan M.G.

Doc. Control D. Ramos Deepak E.P.

QS G. Gobatan

Contract Eng. F. Bustani

AREA PROC. UNIT

Sr. Planning Eng. N.A. Nahed Cost Eng / Plann Eng C. Ashkouti D. Dahwan

Deputy PM Cons. Mngr M,E&I P. Natrajan

Cons. Mngr. Civil N. Saba

Cons. Mang. Mech. Z.Nazzal

Sr. ELEC. Eng.

Sr. Eng. Coord. F. Takieddine (**)

R. Prasad

QA/QC Eng. D. Mankikis (*)

Sr. Safety Eng.

Admin. Mngr.

R. Seyouri

M. Saadeh

QA/QC Insp. Civil A. Perona S. George M. Kumar

Safety Supervisor G. Felix

PR/Passport R. Koshy S. Moolya

Campboss N. Asaad

Mech. services Eng. Y. Hamdani M. Wehbeh

Piping Eng. D. Hanna E. Engalia

ELEC. Eng.

Equip. Eng. H. Rahhal P. Sarudar

Instrument Eng.

N. Faysal

Civil Engineer K. Wehbe

A.A Hajjar

E&I Supervisor

Inst & Cntrl S/C M/S CIMAC

F. Nassar

Civil Gen. F/M J. Chalitta

Proc.Coordintor A. Pacedio (**)

Civil Gen. F/M

T&C - Mech. Eng. H. Jumao A. Basak

T&C - Elec. Eng. Subramanian K.

N. Bou Daher N. Reghupathy

Bldg. Mech. Foreman

Bldg. Mech. Foreman A. ElKhoury

Piping Foreman A. Kirubana J. Olvida R. Mantilla

Equip. Foreman R. Prabhu E. E. Elrizz G. Vijayaku

Fabr. F/M A. Atem Weld. F/M W.A. Rish

E&I Foreman J. Espadelia S. Paniker S. Nassar J. Tiakarajan

Civil Foreman B. Fetiluna

R. Babu

Local Purch. I.A. Kadir

Civil F/M

Transp. Off P. Bala.

Safety Off. A. Tiro J. Page G. Saliba

QA/QC Insp. Mech. R. Marquez A. Mejorada J. Obaob

Shop Drawing S/C M/S DEP

CAD Operator T. Thomas

Sec / Typist J. Mathew V. M. Nair A. Prasadan S. Ali

Scaff. F/M

T&C Sub Contractors

Civil Foreman -

S.ST.F/M B. Sayyah

Engineering S/C M/S Stanley

QA/QC Insp. E&I. F. Medina U. Maheshwaran V. Chinnasamy

Scaff. F/M

Office Boy A. Devasia A. Khan S. Selvaraj

Watchman

Watchman

N. Maccagerr J. Lukose S/C Tes./Bal.

S/C

S/ Contractors

NDT

T. Ahmad

Surveyor Z. Daher Accountant A. Sarkis

Excavation

Ins/Pain

Dewatering Concrete

Ins. Off. G. Tabet

Precast

C. Imp. Holder J. Kantinal M. Samuel Wages Clerk A. Kannan K. Lal Acc. Clerk J. Khan Time Keeper A. Majeed A. Jackson M. Ahmed S. Riyas

Engineer - HEX & ETS R. Ragih

E&I Engineer HEX & ETS G.Faraj

Ass. Eng. - HEX & ETS G. Bitar (*) QA/QC Engineer has the full right to Contact the Area Manager and the Group QA/QC Manager in case he feels a non cooperation om site or he sees a matter that reflects on the Group's global QA/QC system (**) The Sr. Eng. Coordinator & The Procurement Coordinator communicate & interact directly with the Area Procurement office for Design/Procurement related matters.

Mech. Foreman HEX & ETS A. Farhoud

E&I Foreman HEX & ETS B. Shamshad E. Syaiaozy

Civil Engineer HEX Bldgs E. Harb

QA / QC Engineer N. Agtarap

Civil Gen. F/M HEX G. Kodoor

QA / QC Inspector - HEX A. Kumaraswamy

Civil Foreman HEX

QA / QC Inspector - HEX B. Mahendran

Ass. Safety Engineer - HEX & ETS

Safety Inspector HEX & ETS A. Mohd

Civil Foreman HEX

HEX BLDGS & ETS's

Store Keeper

Ass. Str. Keeper T. Botros

APPENDIX 3 LONG LEAD ITEMS LIST Item Description

Manufactures/Supplier Name

1. HV/MV Switchgears Transformers & Starters

Siemens/ABB/Schneider/ Ben Shaw or Approved Equal

2. Chillers

Trane/York or Approved Equal

3. Cooling Towers

Hamon/BAC or Approved Equal

4. Pumps

Goulds/Weir/Flowserve or Approved Equal

5. Heat Exchangers

Alfa Laval or Approved Equal

6. R.O. Plant

Saudi Berkefeld or Approved Equal

APPENDIX 6 LIST OF SUB CONTRACTORS

C.A.T. International Qatar W.L.L proposes to subcontract parts of the works and to supply principal items of the plants as follows:

Work Description

SubContractor

Address

1. Site Investigation

ACTS

P.O.Box 22159, Doha, Qatar

2. Excavation & Backfilling

ACI


3. Dewatering

United Equipment


4. Water Proofing

BMC Qatar

P.O. Box 24407, Doha, Qatar

5. Concrete Works

Somac Group

P.O. Box 7098, Doha, Qatar

6. Pre Cast Concrete Slabs

United Precast

Doha, Qatar

Hempel/Jotun

Doha, Qatar

13. NDT

Qatar Inspection Services

Doha, Qatar

14. Controls & SCADA

Cimac Or Approved Equal

Dubai, U.A.E

7. Doors, Windows,& Louvres 8. False Ceiling 9. Raised Flooring 10. Painting 11. Elevator 12. Roads & Pavement

Note: the above names are only for reference. Other Subcontractors will

be submitted as applicable. Selection will be based on Compliance to specifications and Milestones

APPENDIX 7 CIVIL METHOD STATEMENT LIST Structural / Civil

Reference No

1

Preconstruction Survey

Q06024-IDCP-MOS-CI-001

2

Excavation & Backfilling


3

Reinforcement


4

Concrete Receiving, Testing, Placing & Curing


5

Sub-Structure Waterproofing


6

Major Concrete Placement for Area (3) Raft Foundation


7

Erection of Pre-Stressed Beams & Hollow Core Slabs


APPENDIX 8 MECHANICAL METHOD STATEMENT LIST ME Equipment

Reference No

1

Rigging ,installation and pipe connection of chillers

Q06024-IDCP-MOS-ME-001

2

Rigging , erection and pipe connection of cooling towers


3

Rigging , installation and pipe connection of chilled water pumps


4

Rigging , installation and connection of condenser water vertical turbine pumps


5

Rigging ,installation and connection of plate heat exchangers


6

Installation and connection of tertiary pumps


7

Rigging , installation and connection of expansion tanks


8

Installation and connection of pressurization units

Q06024-IDCP-MOS-ME-008 Q06024-IDCP-MOS-ME-009

9

Installation and connection of in line centrifugal solid separators on first floor

10

Installation and connection of refrigerant silencers on roof


11

Installation of condenser tube cleaning system including 4 way valves


12

Installation of sluice gate valves in cooling tower basins


13

Installation of process valves


14

Rigging , installation and pipe connection of RO system


15

Installation and connection of transfer pumps


16

Installation of inserts (pipe connections) in concrete tanks and cooling tower basins

17

Installation of Overhead cranes


18

Tagging and labelling of pipe,duct and equipment


19

Installation of Antivortex fittings in concrete tanks


20

Pipe handling and storage


21

Installation of process ,HVAC and domestic water pipes


22

Insulation of Process , HVAC and domestic water pipes


23

Jacketing of pipes


24

Fabrication and installation of pipe supports


25

Painting of pipes and supports


26

Hydrotesting of pipes


27

Installation and connection of diesel tanks


28

Introducing new equipment into the system at different stages


29

SMAW Welding


30

Installation and soldering of copper pipes


1

Installation and pipe connection of electric water heaters ( admin part )

Q06024-IDCP-MOS-PL-001

2

Installation of cast iron storm water and drainage pipes .


3

Installation of frames for drainge gratings and manhole covers


4

Installation of floor drains , roof drains and flower bed drains


5

Installation of sanitary fixtures , toilet mixers and accessories ( admin part )


6

Installation of oil interceptors


7

Installation and pipe connection of submersible pumps in basement


Valves

RO System

Common to all Systems

Welding and Soldering

Drainage and Plumbing

Reference No

Reference No

Reference No Q06024-IDCP-MOS-ME-016

Reference No

Reference No

Fire Fighting Systems

Reference No

1

Rigging , Installation and connection of fire pump room equipment and components

Q06024-IDCP-MOS-FP-001

2

Installation of preaction ,deluge , alarm zone valves and siamese connections


3

Installation of fire hose cabinets


4

Installation of fire fighting grooved pipes and fittings ( vertical and horizontal )


5

Installation of diesel pump exhaust with supports up to roof


6

Installation of FM-200 fire fighting system


1

Installation of chemical treatment systems

Q06024-IDCP-MOS-WTR-001

2

Chemical cleaning of pipes

Q06024-IDCP-MOS-WTR-002

1

Rigging , installation and pipe connection of Air handling units

Q06024-IDCP-MOS-AC-001

2

Installation and pipe connection of fan coil units


3

Installation and duct connection of fresh and exhaust fans


4

Galvanised duct and accessories fabrication and installation


5

Internal and external Insulation of galvanised sheet metal duct


6

Jacketing of galvanised sheet metal duct


7

Installation of grilles , diffusers , louvers ,dampers sand trap louvers


Chemical Treatment

HVAC

Reference No

Reference No

APPENDIX 9 E & I METHOD STATEMENT LIST A- HV & MV ELECTRICAL SYSTEM

Reference No

1

11KV Switchgear

Q06024-IDCP-MOS-EL-001

2

3.3KV MCC & Soft Starter


3

415V MCC & VFD


4

11KV/3.3KV Transformer


5

11KV/415V Transformer


6

Emergency Generator


7

Battery Charger & UPS


8

Panel Board & Junction box


9

Earthing System


10

Lightning Protection System


11

Wiring Accessories & Small Power Devices


12

Interior / Exterior & Emergency Lighting


13

Wires & Cables


14

Cable Terminations


15

Raceways


1

Voice & Data System

Q06024-IDCP-MOS-LC-001

2

Security Access Control System


3

CCTV System


4

Fire Alarm System


1

Instuments

Q06024-IDCP-MOS-IC-001

2

PLC / SCADA System

Q06024-IDCP-MOS-IC-002

B- LOW CURRENT SYSTEMS

C- INSTRUMENTATION

Reference No

Reference No

Integrated District Cooling Plant at The Pearl, Qatar

Design Intent Report Conceptual Design Edition Project Number: Q06024 - IDCP FINAL REPORT September 2006 C.A.T. Qatar International W.L.L. Doha, Qatar

Integrated District Cooling Plant at The Pearl, Qatar Q06024-IDCP-RPT-GT-001-REV 3 Design Intent Report

C.A.T. Qatar International W.L.L. Doha, Qatar

Conceptual Design Edition September 28, 2006

Q06024-IDCP-RPT-GT-001-REV 3

Table of Contents

Section 1 - Project Description .....................................................................................................1-1 Section 2 - Civil Engineering and Landscaping Design Statement ..............................................2-1 General......................................................................................................................................2-1 Compliance Statement ..............................................................................................................2-1 Traffic Control ..........................................................................................................................2-2 Paving .......................................................................................................................................2-2 Drainage....................................................................................................................................2-2 Landscaping ..............................................................................................................................2-2 Section 3 - Architectural Design Statement..................................................................................3-1 General......................................................................................................................................3-1 Compliance Statement ..............................................................................................................3-1 Building Exterior ......................................................................................................................3-1 Accessibility and Maintenance .................................................................................................3-2 Containment Requirements.......................................................................................................3-2 Building Interior .......................................................................................................................3-3 Occupancy ................................................................................................................................3-3 Section 4 - Structural Design Statement .......................................................................................4-1 General......................................................................................................................................4-1 Compliance Statement ..............................................................................................................4-1 Design Criteria ..........................................................................................................................4-1 Codes and Standards .............................................................................................................4-1 Design Loads ........................................................................................................................4-2 Material Properties................................................................................................................4-3 Concrete Design....................................................................................................................4-3 Structural Steel Design .........................................................................................................4-3 Material .................................................................................................................................4-3 Structural System ..................................................................................................................4-4

Q06024-IDCP-RPT-CI-001-REV 3

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Section 5 - Mechanical Design Statement ....................................................................................5-1 General......................................................................................................................................5-1 Compliance Statement ..............................................................................................................5-1 Chilled Water Plant Process......................................................................................................5-3 Codes and Standards .............................................................................................................5-3 General..................................................................................................................................5-4 Chillers..................................................................................................................................5-4 Cooling Towers.....................................................................................................................5-6 Chilled Water Pumping Scheme ...........................................................................................5-8 Condenser Water Pumping Scheme......................................................................................5-8 Piping System .......................................................................................................................5-9 Chemical Treatment System .................................................................................................5-9 Miscellaneous .....................................................................................................................5-10 Reverse Osmosis (R.O.) System .............................................................................................5-10 Energy Transfer Stations.........................................................................................................5-11 Heating, Ventilating, and Air-Conditioning ...........................................................................5-11 Standards and Codes ...........................................................................................................5-11 Outdoor Design Conditions ................................................................................................5-12 Indoor Design Conditions ...................................................................................................5-12 Minimum Ventilation Requirements ..................................................................................5-12 System Description .............................................................................................................5-13 Plumbing .................................................................................................................................5-13 Codes and Standards ...........................................................................................................5-13 Water Supply Network .......................................................................................................5-14 Waste Water Drainage ........................................................................................................5-15 Waste Water Drainage ........................................................................................................5-15 Compressed Air ......................................................................................................................5-16 Standards and Codes ...........................................................................................................5-16 Service Air ..........................................................................................................................5-16 Fire Suppression System.........................................................................................................5-16 Codes and Standards ...........................................................................................................5-16 Fire Suppression System.....................................................................................................5-16 Section 6 - Electrical Design Statement........................................................................................6-1 General......................................................................................................................................6-1 Compliance Statement ..............................................................................................................6-1 Extra Low Voltage....................................................................................................................6-2 Applicable Codes and Standards and Basic Design Criteria ....................................................6-2 Ambient Conditions ..................................................................................................................6-3 Electrical Power Distribution....................................................................................................6-3 Overall System Description ..................................................................................................6-3 Emergency Engine Generators .................................................................................................6-4 415/240-Volt Distribution Network..........................................................................................6-4 Uninterruptible power Supply UPS ......................................................................................6-4 Lighting and Emergency Lighting ........................................................................................6-4 Boards ...................................................................................................................................6-5 Circuit Breakers, Residual Current Interrupters, Contactors and Disconnect Switches .......6-5 Cables and Wires ..................................................................................................................6-6 Raceways ..............................................................................................................................6-6 Earthing Network..................................................................................................................6-6 Lightning Protection .............................................................................................................6-7


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Extra Low Voltage....................................................................................................................6-7 Fire Alarm System ................................................................................................................6-7 Voice and Data System.........................................................................................................6-8 Q-Tel GSM Station ...............................................................................................................6-8 Closed Circuit Television System (CCTV) ..........................................................................6-8 Access Control and Door Status System...............................................................................6-9 Section 7 - Control System Design Statement ..............................................................................7-1 General......................................................................................................................................7-1 Compliance Statement ..............................................................................................................7-1 Control Philosophy ...................................................................................................................7-2 Chilled Water System ...........................................................................................................7-5 Cooling Towers.....................................................................................................................7-6 Make-Up Water System........................................................................................................7-6 Blowdown System ................................................................................................................7-6 Electrical System ..................................................................................................................7-6 Instrumentation .........................................................................................................................7-6 Field Instruments ..................................................................................................................7-6 Section 8 - Utility Services Design Statement ..............................................................................8-1 General......................................................................................................................................8-1 Compliance Statement ..............................................................................................................8-1 Chilled Water ............................................................................................................................8-1 Codes and Standards .............................................................................................................8-1 System Description ...............................................................................................................8-2 Potable Water............................................................................................................................8-2 Codes and Standards .............................................................................................................8-2 System Description ...............................................................................................................8-2 Sanitary Sewer ..........................................................................................................................8-2 Codes and Standards .............................................................................................................8-2 System Description ...............................................................................................................8-2 Storm Sewer..............................................................................................................................8-2 Codes and Standards .............................................................................................................8-2 System Description ...............................................................................................................8-3 Section 9 - Maintenance and Accessibility ...................................................................................9-1 General......................................................................................................................................9-1 Compliance Statement ..............................................................................................................9-1 Maintenance and Accessibility .................................................................................................9-1


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Section 1

Project Description

The Pearl, Qatar is a 400 hectare man-made island located off the Eastern coast of Qatar approximately 20 kilometers north of the Doha central business district and east of the West Bay Lagoon. The Pearl Island is connected to the mainland by a causeway. This island is being developed (United Development Company) to include residential and commercial usage arranged around three primary marinas, including hotels, shops, and residential villas and apartments. The roads and infrastructure for The Pearl Island development were completed under a separate contract to support the entire island. The road work consists of roads, bridges, underpass, culverts, surface water drainage, signage, and roadway lighting. The infrastructure work consists of potable water, sanitary sewer, irrigation transmission, chilled water distribution, telecommunications civil work, and electrical distribution. Chilled water has been a primary medium for the transfer of heat from building coils to the refrigeration system since the beginning of heating, ventilating, and air-conditioning design. Providing chilled water from a centrally located plant is an energy efficient and low maintenance means of rejecting heat from air-conditioning systems across a localized campus, whether that campus is a university setting, industrial complex, or large urban site. Over the last five years or more, district energy has exploded on to the scene in the Middle East becoming a necessary utility for new developments. The Integrated District Cooling Plant (IDCP) at The Pearl Project includes a new central chilled water plant to serve the cooling needs for the proposed building construction on the island. Qatar Cool will own and operate this plant upon completion and have established a design-build


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contract with C.A.T. International for the construction of this plant. The new development consists of several high-rise buildings and villas, which will use the chilled water from the IDCP to serve their air-conditioning needs in the most efficient manner possible. Each building will include an energy transfer station or heat exchanger as the “point of use” for chilled water. The chilled water generated at this facility will be provided for the following: • Customer loads at energy transfer stations or heat exchangers. • Customer loads at valve pits (Take-off Chambers). • Plant cooling system including, air handling units and fan coil units. The IDCP is arranged on site to accommodate the construction of the buildings and the island roads and infrastructure and the plant will architecturally be tied into the aesthetics of the surrounding building structures. The plant will have a guaranteed capacity of 115,000 tons expandable to 120,000 tons (ARI Tolerance) using forty-six (23 pairs) 2,500-ton nominal electric motor-driven centrifugal chillers. Provisions will be incorporated into the design of the IDCP for future expansion using two 2,500-ton nominal electric motor-driven chillers. The chillers will be in a series-series, counter flow arrangement utilizing a direct primary pumping scheme. The heat picked up by the chiller refrigeration cycles will be rejected via twenty-four 5,000-ton cooling tower cells. Each cooling tower cell will serve up to two chillers and will be piped in a headered arrangement such that each cell can be used with any combination of chillers. The cooling towers will be constructed of fiberglass and will be field-erected on the roof of the plant to conserve space on the site for other use. Aesthetic enhancements to the new building will visually compliment the architecture of the area per UDC approval. Utilities serving the IDCP will be installed by the “Infrastructure Contractor” under a separate contract with the Owner. The chilled water distribution system will routed to a vault at the limits of the plant site as depicted in the Conceptual Design Drawings. The plant will hydraulically operate as two independent facilities; each connected to new underground chilled water distribution systems. Chilled water will be delivered to network through a constant flow, direct primary pumping scheme. The Pearl Chilled Water Distribution System will be a looped, underground distribution network served by the IDCP and installed under a separate infrastructure contract as described above. New high-voltage transformers will be provided by the infrastructure contractor and connected to the IDCP to serve the power requirements of the plant. The control system will utilize a SCADA control system for monitoring and operation of the new equipment, except for the chillers, which will be started locally. This system will allow control of the new facility from operator workstations, located in the new plant control room. The system will utilize digital communications for remote monitoring and/or control of the various systems within the plant.


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Section 2

Civil Engineering and Landscaping Design Statement

General This section of the Design Intent Report includes the narrative description of the Civil Engineering and Landscape Site Planning for the Integrated District Cooling Plant (IDCP) at The Pearl, Qatar. Site survey data obtained during the course of this project will form the basis for the development of the grading and paving design. Discussions between the Owner, Qatar Cool, PMC, the Contractor, C.A.T. International (CAT), and the Design-Build Engineer, Stanley Consultants are detailed in Exhibit A – Project Correspondence.

Compliance Statement The Civil Engineering and Landscape Site Planning design will comply with all portions of the Tender Documents prepared for Qatar Cool and issued by DAR during the tender phase. These documents include the general requirements, tender specifications, tender drawings, and the appropriate addendums and tender circulars issued for clarification, except as noted below: • Plant Arrangement: The IDCP will be based upon the plant arrangement from the Alternate 2 bid proposed by CAT and accepted by Qatar Cool prior to contract award. • Site Layout: The latest revisions to the U-07 plot limits will form the basis of the site layout and grading and paving design. • Access Road Width: Service access roads around the plant will be wider than 6 meters at areas designated for equipment installation and removal from the plant building as indicated in Section Q0547/a-SPC-TR-01 REV 1 of the Tender Specifications. Paved equipment staging areas will be provided at these locations to facilitate those operations.


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Traffic Control Construction activities will be coordinated to minimize the impact on traffic flow in the vicinity of Plot U-07. In general, traffic generated by the IDCP is low and as such is not expected to impact the traffic of the area surrounding Plot U-07.

Paving A new service access drive will be provided to the site from the north and will serve the normal operational traffic of the IDCP as well as to support maintenance and delivery activities for the plant. All paving will conform to local codes and standards as well as Section 6 of QCS 2002.

Drainage The drainage collection system will run along the roads surrounding the site and will consist of storm sewer piping, manholes, gullies, and swails. Storm water run-off will be collected by the gullies and swails. Manholes will be placed not more than 75 meters apart and will be used for inspection of the storm water system.

Landscaping The soft landscape at ground level will use tree groups in stone mulch (10-cm crushed stone mulch to cover all unplanted and unpaved areas), towards the plot boundaries, providing framed views of the building, with ground cover and shrubs closer to the building, screening the service ring road and providing the first tier of planting to the building. Trees should be of a single, spreading, flowering variety, shrub to comprise a single type of ornamental grass such as Pennisetum alopecuroides, and ground cover of a spreading flowering succulent variety. The same ground cover and ornamental grass shall be used to the planter behind the battered ground floor parapet wall. All planting for the project will be appropriate to the exposed seashore conditions of the site and island. Trees to be minimum 250-cm overall height, shrubs and ornamental grasses grown. The IDCP building will include planters as required to meet the agreed upon architectural appearance of the plant relative the surrounding area.


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Section 3

Architectural Design Statement

General This section of the Design Intent Report includes the narrative description of the architectural design for the Integrated District Cooling Plant (IDCP) at The Pearl, Qatar. Discussions between the Owner, Qatar Cool, PMC, the Contractor, C.A.T. International (CAT), and the Design-Build Engineer, Stanley Consultants are detailed in Exhibit A – Project Correspondence. The IDCP will be designed as an attractive, functional, building that acknowledges and expresses the buildings purpose. The new building and cooling towers should be considerate of the appearance, scale, and other features of the surrounding structures and at the same time, minimize the impact of the building on the surrounding visual and aesthetic environment, as well as provide for future horizontal expansion.

Compliance Statement The Architectural design will comply with all portions of the Tender Documents prepared for Qatar Cool and issued by DAR during the tender phase. These documents include the general requirements, tender specifications, room data sheets, tender drawings, and the appropriate addendums and tender circulars issued for clarification, except as noted below: • Plant Arrangement: The IDCP will be based upon the plant arrangement from the Alternate 2 bid proposed by CAT and accepted by Qatar Cool prior to contract award.

Building Exterior The design must consider the building’s physical and visual impact on the site and its relative scale to surrounding structures. There are three main components to the proposed building; the operational plant, the cooling towers and the Administration Building.

Q06024-IDCP-RPT-AR-001-REV 3

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The operational plant is a two floor building; ground with a double height, first and partial basement. There are two rows consisting of 12 cooling towers each that sit on top of the operational plant. The Administration Building is a three floor building; ground, mezzanine and first. The exterior is concrete structure and blockwork with grooved plaster and paint finish, in addition to powder coated aluminum louvers at the transformers areas, the Administration Building will have powder coated aluminum curtain walls and windows to allow natural light to filter into the building.

Accessibility and Maintenance Architectural features will reinforce the functional and maintenance requirements of the facility and will not impede normal operations. • Overhead doors will be positioned and aligned to provide unimpaired movement through the full width of the door to access aisles. Overhead doors and access aisles will be provided to permit unobstructed removal and replacement of every major piece of equipment and their respective subassemblies. A service elevator rated at 1-ton lifting capacity will provide vertical access between the ground, mezzanine and first floors of the Administration Building. The roof of the operational plant will be accessible by three individual stair towers. Four cranes will be provided at the ground floor of the operational plant to allow handling spare parts and maintenance of the chillers and pumps. One crane will be provided at the roof floor of the operational plant to allow handling spare parts and maintenance of the cooling basin pumps. Access opening (6000 x 3000 cm) will be provided in the center of the operational plant to handle equipment from the ground floor to the first and roof floors. Access hatches will be provided to handle the generators and pumps to the basement. Refer to Section 9 for more details on maintenance and accessibility.

Containment Requirements Electrical areas containing oil-filled transformers will be designed with passive containment provisions as required by the National Electrical Code and Stormwater Pollution Prevention Plan to prevent the accidental release of oil and to facilitate clean up and removal of spilled oil.


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Building Interior The interior of the plant expansion is comprised of the basement, main operating floor, and mezzanine. The basement houses piping, pumps and water tanks related to the plant operations and a generator room containing two generators. Chillers and pumps are located on the main operating floor (ground). The first floor provides RO system as well as space for HVAC and electrical equipment.

Occupancy The plant will be occupied 24 hours per day. The floor, walls, and ceiling of the operational and storage areas are all concrete. The floors have a transparent sealer. The walls and ceilings are painted for better light. The lab and control room will have resilient tile. The lab has epoxy resin worktops with integral sinks. Life safety features include an automatic sprinkler system and a fire alarm system.


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Section 4

Structural Design Statement

General This section of the Design Intent Report includes the narrative description of the structural systems for the Integrated District Cooling Plant (IDCP) at The Pearl, Qatar. Discussions between the Owner, Qatar Cool, PMC, the Contractor, C.A.T. International (CAT), and the Design-Build Engineer, Stanley Consultants are detailed in Exhibit A – Project Correspondence. This section includes the design criteria, subsurface conditions, foundations, building basement walls, concrete slabs on grade, operating floor over basement, and interior walls within the IDCP. Two expansion joints will be provided for the operational plant building and one expansion joint will be provided between the operational plant building and the support space building.

Compliance Statement The Structural design will comply with all portions of the Tender Documents prepared for Qatar Cool and issued by DAR during the tender phase. These documents include the general requirements, tender specifications, room data sheets, tender drawings, and the appropriate addendums and tender circulars issued for clarification, except as noted below: • Plant Arrangement: The IDCP will be based upon the plant arrangement from the Alternate 2 bid proposed by CAT and accepted by Qatar Cool prior to contract award.

Design Criteria Codes and Standards The following codes and standards will be used in conjunction with the structural design: • BS6399: Code for Loading for Buildings • BS8110: Structural use of Concrete

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• Uniform Building Code (UBC) for Seismic Loads Design Loads The Uniform Building Code (UBC) 1997 Edition, with the following criteria: • Codes: BS 6399: Part 1 for dead and imposed loads CP3 Chapter V, Part 2, for wind loads, UBC for seismic loads. • Dead Loads: - Concrete Unit Wt. = 24.00 KN/m3 - Floor Covering (Typical Floors) = 2.00 KN/m2 - Partition Loads (Typical Floors) = 2.50 KN/m2 for block work and 1.00 KN/m2 for Gypsum Partition. - Floor Covering (Roof) = 2.50 KN/m2 • Live Loads: The live loads will be based upon the following: - Equipment Weight: Location and magnitude of loads will be coordinated with the mechanical design. - Pipe Support Loads: Location and magnitude of loads will be coordinated with the mechanical design. - Cooling Tower Weight: Location and magnitude of loads will be coordinated with the mechanical design. These loads will include the basin water weight on roof slab. - Water Tanks: Location and magnitude of loads will be coordinated with the mechanical design. • Wind Loads: The wind load will be based upon a basic wind speed of 45 mps. • Seismic Loads = Zone 2A Seismic Risk • Load Combinations: - 1.40 x D.L. + 1.60 x Live loads - 1.40 x D.L. + 1.60 x Lateral Loads - 1.20 x D.L. + 1.20 x L.L + 1.20 x Lateral Loads • Foundations: - Foundations will be shallow foundations of raft type. - The IDCP will have two levels for the raft foundation. The first will be under the basement floor on rock and the second will be divided into two parts on another raft foundation:


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- One level will be on compacted soil and the operational plant building will have a shallow foundation, but with isolated footings or strip footings depending upon the column loads as well as the final soil bearing capacity. The final bearing capacity of the soil will be determined from the geotechnical report and its recommendations. The foundation type and its design parameters will be finalized as per the recommendations of the geotechnical report. Material Properties • Concrete of Characteristic Strength for Columns = 75 N/mm2, for Beams = 50 N/mm2, for Other Elements = 40 N/mm2 • Steel Reinforcements of Characteristics Yield Stress = 460 N/mm2 Concrete Design Design shall be in accordance with BS 8110: Structural Use of Concrete. Structural Steel Design Design shall be used on the following codes and standards: • BS 5950-1:2000: Structural Use of Steelworks in Buildings • BCSA: British Constructional Steel Association Material • Concrete: The classes of concrete are indicated below and reflect the 28 days cube strength, Fc. Table 4-1 Classes of Concrete Concrete Class

Fc (Mpa)

Construction

A

75

Columns

A

50

Beams

A

40

Other R.C. Elements

B

20

Blinding

• Cement: Ordinary Portland Cement (OPC) will be used for superstructure and moderate Sulphate Resisting Cement (SRC) Type II will be used for structural elements in contact with the soil. • Reinforcement: All reinforcement will be deformed high tensile hot rolled steel having a minimum yield strength (fy) equal to 460 Mpa and will conform to BS4449.


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• Structural Steel: Design will be based upon the following codes and standards: - Steel Sections: BS 4, Part 1, Grade 43 (having a minimum yield strength of 275 Mpa) Grade 50 (having a minimum yield stress of 35 Mpa) or equivalent. - Steel Tubes and Pipes: To BS 4848, Part 2 (having a minimum yield strength of 345 Mpa) or grade 50 having a minimum yield strength of 355 Mpa) or equivalent. - Steel Bolts, Nut Washers: To ISO 4014, ISO 4032 and ISO 7089 respectively. Structural System The structural concept is driven by functional, economical and efficiency considerations. The systems adopted will be chosen to fulfill the specific architectural and functional requirements as well as proper manipulation of the assigned areas.


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Section 5

Mechanical Design Statement

General This section of the Design Intent Report includes the narrative description of the chilled water plant process, heating, ventilating, air-conditioning, plumbing, and fire suppression systems for the Integrated District Cooling Plant (IDCP) at The Pearl, Qatar. Discussions between the Owner, Qatar Cool, PMC, the Contractor, C.A.T. International (CAT), and the Design-Build Engineer, Stanley Consultants are detailed in Exhibit A – Project Correspondence.

Compliance Statement The Mechanical design will comply with all portions of the Tender Documents prepared for Qatar Cool and issued by DAR during the tender phase. These documents include the general requirements, tender specifications, room data sheets, tender drawings, and the appropriate addendums and tender circulars issued for clarification, except as noted below: • Plant Arrangement: The IDCP will be based upon the plant arrangement from the Alternate 2 bid proposed by CAT and accepted by Qatar Cool prior to contract award. • Thermal Storage: Thermal storage was eliminated from the project with Alternate 2 bid proposed by CAT and accepted by Qatar Cool. • Number of Chillers: Thermal storage was removed with the Alternate 2 bid proposed by CAT and accepted by Qatar Cool. To make up the difference in capacity the number of chillers was increased over what was shown on the Tender Drawings and listed in Section 60, Paragraph 15.1.4.2.b of the Tender Specifications. • Chiller Arrangement: The chillers will be arranged in pairs using a series-series, counterflow arrangement instead of the series-parallel counter-flow arrangement indicated on the Tender Drawings and Section 9, Paragraph1.1.17.1 of the Tender Specifications.

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• Chiller Water Boxes: The chiller refrigerant condenser and refrigerant evaporator will be provided with non-marine type water boxes instead of the marine-type water boxes indicated in Section 60, Paragraph 15.2.7.4.a of the Tender Specifications. In the absence of the marine water boxes, the chiller tubes can be accessed by removal of the connecting pipes at the chiller by means of grooved-end lock (Victaulic) connections followed by removal of the water box cover. • Chiller Connections: The chiller refrigerant condenser and refrigerant evaporator will be provided with stub-out type connections and mechanical coupling grooves suitable for bolted clamp-type coupling with grooved-end lock instead of flanged connections indicated in Section 60, Paragraph 15.2.7.4.b of the Tender Specifications. See previous exception for a discussion on access to the tubes. • Chiller Condenser Tube Cleaning: Each chiller condenser will include a tube brush cleaning system that will scour the tubes clean by reversing the flow through the condenser using automatic control valves as shown in the piping configuration on the Drawings (Q06024-IDCP-M-I-614). The Tender Drawings show the use of four-way valves for this operation; however, four-way valves are not available in the sizes needed. • Number of Cooling Towers: Thermal storage was removed with the Alternate 2 bid proposed by CAT and accepted by Qatar Cool. To make up the difference in capacity the number of cooling towers was increased over what was shown on the Tender Drawings and listed in Section 60, Paragraph 16.1.4.1.a of the Tender Specifications. • Cooling Tower Design Conditions: The cooling tower flow rate to each cell will be 11,000 gpm and the condenser water temperature differential will be 13°F. The flow rate and range differ from those specified in Section 60, Paragraph 16.3.9 (3 gpm per ton at a 10°F range). The design conditions selected allow for a higher cooling tower capacity per square foot of building and provides the guaranteed capacity and efficiency at the chiller. Alternate design conditions to the traditional 3 gpm per ton are becoming more prevalent for this reason. Reference “Optimizing Condenser Water Flow Rates” presented by Bill Liegois at the 2006 IDEA Campus Energy Conference. • Number of Basins: Each cooling tower will be divided into three basins at the building control joint locations. This differs from the Tender Drawings which shows two independent basins for each cooling tower. This modification is necessary to accommodate the structural design of the building. Each of the three basins will be connected by equalization lines for common level control. • Condenser Water Filtration: The condenser water system will include three side-stream centrifugal filter separators for each 12-cell cooling tower connected to the respective supply headers. The side-stream flow rate will be equal to 10 percent of the total condenser water flow rate. The Tender Drawings show smaller units both on the headers and at each chiller. • Chilled Water Pumping Scheme: The chilled water pumping scheme will be a direct primary (constant speed) system that varies flow to the distribution system by staging chillers and pumps on and off. This differs from the Tender Drawings and Section 60, Paragraph 9.3.5 of the Tender Specifications, which calls for a primary-secondary system.


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This modification will provide a more energy efficient system by eliminating the neutral bridge bypass, which can lower chilled water return temperatures and contribute to the phenomenon known as “Low ∆T Syndrome.” • Air Separation: DAR requested Stanley Consultants to provide technical justification for the elimination of the air separators from the IDCP. ASHRAE is not specific regarding the use of air separators within chilled water systems, except in regards to smaller building type systems. Roy Ahlegren of ITT Industries gave a presentation for the University of Wisconsin's Chilled Water Plants for Central District Cooling Seminar in April 2006. He identified the following advantages of closed loop systems as they relate to air entrapment: - Oxygen additions are limited due to the lack of interface between air and water during normal operation. - Pressures and temperatures minimize air coming out of solution within systems. This is not the case for heating systems, which typically require air separation. - The use of bladder-type expansion tanks further reduces the interface between air and water. - Permanent energy penalty due to pressure drop of separators. • Chilled Water Strainers: The Tender Specifications (Section 60, Paragraph 14.2.4.2) indicate that basket strainers are to be provided for the chilled water system. However, the vertical dimensions of the basket strainers are not conducive to making the equipment connections. Stanley Consultants recommends using Tee Strainers in lieu of the basket type to resolve this conflict. The tee strainers will be in compliance with the performance requirements of the basket strainers as specified (i.e. 5/32” perforations).

Chilled Water Plant Process Codes and Standards The chilled water system, equipment, and components will be designed in accordance with the applicable industry standards and shall conform to the provisions of the latest issue of applicable U.S.A. codes and standards including but not limited to the following: •

Uniform Building Code (UBC)

•

Uniform Mechanical Code

•

National Fire Protection Agency Codes and Standards (NFPA) or local equivalent

•

American Society of Heating, Refrigeration and Air-Conditioning Engineers (ASHRAE)

•

American Society of Mechanical Engineers (ASME)

•

American Society for Testing and Materials (ASTM)

•

American National Standards Institute/Hydraulic Institute (ANSI/HI) Pump Standards

•

Applicable Local Codes and Standards

•

Other standards listed in the Tender Documents


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General The Integrated District Cooling Plant at The Pearl Project includes a new central chilled water plant to serve the cooling needs for the proposed building construction on the island. The new development consists of several high-rise buildings and villas, which will use the chilled water from the IDCP to serve their air-conditioning needs. Each building will include an energy transfer station and/or heat exchanger as the “point of use” for chilled water. The IDCP is an independent chilled water plant designed for an ultimate capacity of 120,000 tons and an initial capacity of 115,000 tons. The size and number of the chillers were selected based upon the Alternate 2 Bid proposed by CAT and accepted by Qatar Cool prior to award of the contract. These discussions resulted in the decision to use 2,500-ton nominal electric motor-driven centrifugal chillers arranged in pairs using a series-series, counter-flow configuration. To achieve the initial capacity, the plant will include 23 chiller pairs arranged as shown on Drawings (Q06024-IDCP-A-101). Provisions will be incorporated into the design of the IDCP for the future expansion of the plant to its ultimate capacity using one additional chiller pair. The main equipment and auxiliaries for the IDCP include: •

Chillers – Arranged in pairs using a series-series, counter-flow configuration.

•

Cooling Towers.

•

Chilled Water Distribution Pumps (Constant Speed).

•

Condenser Water Pumps (Constant Speed).

•

Refrigerant Transfer Unit with Pump-Out Receiver.

•

Reverse Osmosis (R.O.) Equipment (i.e. Salt Water R.O. Units, Brackish Water R.O. Units, Sand Filters, Pumps, and Tanks).

•

Continuous Condenser Water Filtration Equipment.

•

Water Treatment System.

•

Cooling Tower Blowdown System.

•

Electrical Switchgear, Transformers, etc. (see Section 6).

•

Plant Control System (see Section 7).

Chillers Forty-six (23 pairs) 2,500-ton nominal electric motor-driven centrifugal chillers will be installed as a part of this project. Chiller pairs will be rated in accordance with ARI 550/590 based upon the specified ARI and zero tolerance performance. In addition, the chillers will operate without loss of capacity at ambient temperatures as high as 104°F. Each chiller will be factory assembled and tested and located as shown on the Drawings (Q06024-IDCP-A101). The chillers will be designed to cool 7,500 gpm (1.5 gpm per ton) of chilled water from 56°F to 40°F and reject that heat to 11,000 gpm (2.2 gpm per ton) of condenser water. The design water temperature rise across the condenser will be from 92°F to 105°F.


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The chiller compressor will not exceed a sound pressure level of 85 dBA at a distance of 3 feet from the compressor, condenser, and evaporator during full load operation. This sound pressure level is based upon a reference pressure of 20 micro-pascals. In addition, the chillers will be used in a direct-primary (constant speed) pumping scheme consisting of pumps that are operated in conjunction with the chillers. This will allow the system to vary the total flow to match the load of the distribution system, but maintain a constant flow through the chiller evaporator. Refer to Section 7 for Control Systems Design Statement. The refrigeration cycle will utilize R-134a or R-123 as its refrigerant and the chiller components and auxiliaries are as follows: •

Refrigerant Condenser

•

Refrigerant Evaporator

•

Economizer (As Required)

•

Compressor

•

Couplings

•

Compressor Motors

•

Auxiliary Motors

•

Purge System (R-123 Only)

•

Vacuum Prevention System (R-123 Only)

•

Compressor Motor Starters

•

Auxiliary Motor Starters

•

Control System

•

Accessories and Associated Piping

•

Structural Steel Base with Seismic Restraints and Vibration Isolation Devices

The condensers and evaporators will be of horizontal, shell and tube design in a single-pass configuration. The design will be stamped in accordance with ASME Section VIII. Shell, tube sheets and supports will be constructed of carbon steel and the tubes of seamless copper. Tubes will be 3/4-inch OD enhanced bore with integral fins and have a maximum fouling factor of 0.00025. In addition, the evaporator and condenser pressure drop will not exceed 15 feet of head loss. Each chiller condenser will include a tube brush cleaning system that will scour the tubes clean by reversing the flow through the condenser using automatic control valves as shown in the piping configuration on the Drawings (Q06024-IDCP-M-I-614). The water boxes will be of welded, non-marine carbon steel construction with mechanical coupling grooves suitable for welding or bolted clamp-type coupling. Refrigerant side relief


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valves will be provided and designed in accordance with ANSI B9.1/ASHRAE 15 safety code. A refrigerant sub-cooler or flash-type economizer will be provided with the chillers, at manufacturer’s option, to improve cycle efficiency. The compressor will be open or hermetic drive, horizontally-split centrifugal-type, and driven by an electric motor. Open drive motors will be totally enclosed, water cooled (TEWAC) type using condenser water at a temperature of 92°F. The chiller will be guaranteed to provide 100 percent of rated capacity for any given pair of chillers, while not exceeding 0.748 kW per ton of electrical usage. Performance testing will be conducted in accordance with the latest edition of ARI 550/590. Cooling Towers Two, 12-cell, 60,000-ton cooling tower cells will be installed as a part of this project. Condenser water leaving the chillers enters the tower through the distribution header and is discharged through nozzles. The water falls through the fill, while air is drawn up to the fan stack in a counter-flow fashion. Heat is rejected to the air through an evaporative cooling process. Air is drawn through each cooling tower at a design inlet wet bulb temperature of 87°F to provide the required evaporative cooling. The cooling tower cells will be located on the roof of the plant and designed as an integral architectural element of the facility. Exterior treatments will blend with the overall architectural theme of the plant. The tower components include: •

Fan

•

Motor (Variable Speed)

•

Fill

•

PVC Drift Eliminators

•

Distribution Piping and Nozzles

•

Concrete Basin and Fiberglass Walls

•

Internal Support System

•

Chemical Water Treatment System

The cooling towers will be designed for wind loading in accordance with the 1997 UBC for 90 miles per hour wind and an exposure D. In addition, the cooling towers will be designed in accordance with the 1997 UBC for a Seismic Zone 2A. The tower cells will be constructed of double wall, FRP using structural shapes of pultruded fiberglass components having a flame spread rating of less than 25. The tower basin will be elevated above the roof level to allow for adequate clearance for the condenser water pumps and will be constructed of concrete.


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Each cooling tower cell will be divided into three basins at the building control joint locations. These basins will be connected through equalization lines that will be designed to maintain a maximum differential in water levels of 1 inch. The fans will be multi-blade propeller type constructed of fiberglass blades and an epoxy coated, galvanized steel hub. The fan will be electric motor-driven through reduction gears and a variable frequency drive (VFD). The fan motors will be totally enclosed, fan-cooled (TEFC) type and located outside of the air stream. The variable speed drive allows for loadfollowing at the tower as well as reduction in ambient noise during off-peak cooling hours. The heat transfer medium will be cross-corrugated polyvinyl chloride (PVC). In addition, the cooling towers will include multi-pass, wave form drift eliminators constructed of PVC and capable of reducing the cooling tower drift to 0.0005 percent of the condenser water flow rate. The cooling tower distribution system and nozzles will provide an even distribution of water over the fill and be capable of allowing flow reductions down to 50 percent of design flow without modifications or adjustments. In addition, the pressure drop across a nozzle will not exceed 2 psid. The cooling towers will be guaranteed to provide 100 percent of rated capacity at the design conditions listed above. Performance testing will be conducted by an independent impartial third party in accordance with the latest edition of CTI Publication ATC-105. Cooling towers shall not exceed sound pressure level of 50 dBA at 50 meters perpendicular from tower wall between hours of 8:00 p.m. to 8:00 a.m. by any single cooling tower cell. The sound pressure levels are in decibels (dB) relative to standard reference pressure of 0.0002 Dynes/sq. cm. Distances listed are from the bottom edge of air inlets facing outward from the plant. Performance testing will be conducted by an independent impartial third party in accordance with the latest edition of CTI Code ATC-128. Make-up water and chemical treatment for the cooling tower water will be added at the basin of each tower and controlled on a tower-by-tower basis. The chemical injection system will be designed to allow for even distribution of chemicals within the basin. In addition, three side stream centrifugal filter separators will be provided for each 12-cell tower for removal of suspended solids. The side stream filtration system will be based upon a flow rate equal to 10 percent of the total condenser water flow rate. The condenser water will have the following minimum characteristics: •

pH Range: 8.0 to 9.0.

•

Chlorides (NaCl): <200 ppm.

•

Sulfate (SO4): <100 ppm.

•

Sodium Bicarbonate (NaHCO3): Negligible.

•

Calcium (CACO3): <50 ppm.

•

Oil or Grease: Negligible.


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•

Silica (SiO2): Negligible.

•

Maximum Water Temperature: 110ºF.

Cooling tower blowdown will be based upon two to six cycles of concentration depending upon the operating scenario. The sanitary system will be sized accordingly. Chilled Water Pumping Scheme The chilled water pumping scheme will be of direct primary design with constant speed distribution pumps. It consists of a single, variable volume chilled water loop, which combines the chilled water plant and distribution systems. In order to vary chilled water flow to match cooling load (position of two-way control valves), this pumping scheme allows the flow from the plant to adapt to varying distribution conditions instead of having an independent secondary loop. The chilled water pumps perform double duty by both circulating chilled water through the chillers as well as the piping network. The flow is varied by adjusting the quantity of chillers/pumps that are in operation. Each chilled water distribution pump serves a dedicated chiller pair and will be sized for 7,500 gpm (16°F ∆T), 330 feet of head (estimated), and a maximum motor power of 900 Hp. The pumps will be motor-driven centrifugal, horizontal split case type with double suction and single stage features. The casing will be cast or ductile iron as required for the maximum working pressure. The impeller will be constructed of bronze, fully enclosed, and dynamically balanced. The pumps will include single, cartridge-type mechanical seals, each with an API Plan 11 mechanical seal flushing system. Pump motors will be in accordance with IP 54 and non-overloading throughout the entire pump curve. The pump efficiency will not be less than 85 percent. Condenser Water Pumping Scheme Condenser water pumps will be installed in a headered arrangement to allow any cooling tower cell to serve any chiller on a given condenser water system. These pumps will be located on the roof at each cooling tower cell and the pump discharges connected in the headered arrangement. The condenser water piping enters the IDCP through two pipe shafts located in the center of the roof, as shown on the Drawings (Q06024-IDCP-MP-104). Each condenser water pump serves a dedicated cooling tower and will be sized for 11,000 gpm (13°F ∆T), 115 feet of head (estimated), and a maximum motor power of 400 Hp. The pumps will be motor-driven centrifugal, vertical turbine type. The discharge head assembly will be constructed of high grade cast iron or fabricated steel and include an ANSI Class 150 discharge flange. The impeller will be constructed of silicon bronze, enclosed or semi-open, and dynamically balanced. Pump motors will be in accordance with IP 54 and non-overloading throughout the entire pump curve. The pump efficiency will not be less than 80 percent.


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Piping System As previously stated, the chilled water piping system will be arranged in a direct primary fashion. The chilled water and condenser water pipe sizing will, in general, be based upon the following criteria: •

Maximum design velocity of 15 feet per second.

•

Maximum head loss of 2.0 feet per 100 feet of pipe.

The piping will be constructed of carbon steel, designed in accordance with the requirements of ASME B31.1 and shall have a minimum thickness of standard weight pipe, but wall thickness will be sufficient for the pressure class of the system. The major chilled water piping headers will be 48-inch diameter and will be located within trenches. This maintains a “clean” operating floor and simplifies normal operation and maintenance functions within the plant. The major condenser water headers will be 60-inch diameter and are located above the center access aisle. These headers will be supported from structural steel below that is directly connected to the columns. See Drawing Q06024-IDCPMP-100. The chilled water system is divided into two hydraulically independent loops, each of which serves the looped network piping system. Two separate pairs of chilled water headers leave the IDCP and connect independently into the network piping. Each of the two headered systems will include a bypass line between the supply and return headers with a selfcontained, back-pressure regulating valve. The purpose of this valve is to protect the chilled water system from over pressurization. Manual isolation within the system will typically be through the use of butterfly valves in accordance with Section 60, Paragraph 7.2.5. Wafer-style check valves will be included at the discharge of each pump. All valves will be rated in accordance with the system design pressure and temperature. Pipe supports for the IDCP will be in accordance with Section 60, Part 8 of the Tender Specifications as well as the applicable MSS Standards. Chemical Treatment System The chemical treatment system shall include corrosion coupons, conductivity sensors, makeup water system and metering, chemical storage, piping, and injection equipment. The chilled water system will be treated for protection against corrosion as a primary consideration and microbiological growth as a secondary consideration. Corrosion within the chilled water system will be controlled at 2 mpy maximum. Chemicals will be injected into the system using suitable sized, skid-mounted dosing pumps. The condenser water system will be treated for protection against deposition, corrosion, and microbiological growth. Corrosion within the condenser water system will be controlled at 3 mpy. Microbiological growth will be controlled using biocide and effective bio-dispersant, as required, to operate at pH above 8.0.


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Condenser water chemical treatment system shall include conductivity controlled bleed down, level controls, dosing pumps for bio-dispersant and chlorine donor, chemical storage tanks, and controls. Chemicals will be injected into the system using suitable sized, skidmounted dosing pumps. Miscellaneous In addition to the main equipment and piping, the process is supported by several auxiliary systems: •

A mobile refrigerant transfer unit with pump-out receiver sized for the refrigerant charge of one chiller when the tank is 80 percent filled with refrigerant at 122°F.

•

Chilled water expansion tanks will be provided on the system to allow for the thermal expansion and contraction of the water. The pressure at the expansion tanks will be set based upon maintaining a minimum of 4 psig at the highest elevation within the system.

•

Chilled water make-up will be provided from the site potable water service and connected to the system at the expansion tank location.

•

Cooling tower make-up water will be provided from a combination of three sources: - Site Potable Water: 5,000 cubic meters per day (920 gpm). - Reverse Osmosis (R.O. System): 7,000 cubic meters per day (1,285 gpm). - Treated Sewage Effluent (TSE): 10,000 cubic meters per day (1,835 gpm).

Reverse Osmosis (R.O.) System A portion of the cooling tower make-up water will be supplied from a Reverse Osmosis system located with the IDCP. Sea water will be pumped from a sea water pump station near the IDCP and supply salt water to the raw water tank located within the basement of the plant. This raw water is then treated and blended with site potable water and treated sewage effluent (TSE) to provide the total make-up water needs for the cooling towers. The R.O. water treatment system will be designed as a complete clean-in-place skid, sufficient to produce 7,000-cubic meters per day (1,285 gpm) of finished water and will be capable of continuous operation. The gulf sea water will be supplied at a nominal salinity of 47,000 mg/l total dissolved solids at a temperature range of 68°F to 97°F. The R.O. system product water salinity will be less than 500 mg/l total dissolved solids under all pressure and temperature conditions with a minimum 40 percent recovery of feed water flow. At a minimum, the R.O. System will consist of the following: • Feed Water Chlorination • Feed Water Pre-Treatment Filtration • De-Chlorination Chemical Feed System


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• Acid Feed and pH Control Systems • Anti-Scalant Chemical Feed System • R.O. Vessels and Membranes • High-Pressure Feed Pumps • Post R.O. pH Adjustment and Chlorination Feed • Interconnecting Piping, Valves, and Accessories • Packaged Control System

Energy Transfer Stations Chilled water from the IDCP is delivered, via the distribution network, to several energy transfer stations (ETS) or Heat Exchangers (HEX). These serve as the division between the IDCP and the customer. The heat from the building HVAC system is rejected to the plant side chilled water via the plate and frame heat exchanger. The ETS plant rooms are located within the buildings they serve, while the HEXs are located in independent buildings and often serve multiple buildings. The ETS/HEX Plant consists of the following: • Plate and Frame heat Exchangers • Piping, Instrumentation, and Valves • By-Pass Facility • Controls, including PLC based system and control valves The plate and frame heat exchangers will be in accordance with Section 60, Part 18 of the Tender Specifications and will be sized to meet the cooling load of the customer to which they serve.

Heating, Ventilating, and Air-Conditioning Standards and Codes The HVAC systems, equipment, and components will be designed in accordance with the applicable industry standards and shall conform to the provisions of the latest issue of applicable U.S.A. codes and standards including but not limited to the following: •


•

Uniform Mechanical Code (UMC)

•

Uniform Fire Code (UFC)

•

National Fire Protection Association Codes and Standards (NFPA) or local equivalent

•

American Society of Heating, Refrigeration and Air-Conditioning Engineers (ASHRAE)

•



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•


•

SMACNA Standards.

•

Applicable Local Codes and Standards.

•

Other standards listed in the Tender Documents.

The Project will comply with the international standards usually in practice in the region and specifically in Qatar. The particular standards and codes are specified each under its related trade in this report. Outdoor Design Conditions •

Summer: - Dry Bulb Temperature: 46°C - Wet Bulb Temperature: 31°C

Indoor Design Conditions Indoor design conditions of conditioned plant space: •

Summer: - Dry Bulb Temperature (Offices): 24°C, 50 percent relative humidity - Dry Bulb Temperature (Plant and Electrical Areas): 28°C to 30°.

Indoor design conditions of Transformer Area: •

Summer: - Dry Bulb Temperature: 50°C

Minimum Ventilation Requirements The minimum outdoor ventilation required for each space will be provided per ANSI/ASHRAE 62-2004. The plant floor will be provided with an energy recovery unit for supplying outdoor ventilation air. Fresh Air Input Rate: •

Occupied Areas: 8 l/s

•

Lobby: One Air Change per Hour

•

Toilets Ten Air Changes per Hour

•

Chiller Area: 2.6 L/S/M2


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System Description The building will be served by a chilled water branch that will be tapped off the main chilled water header with pressure reducing station (as required) to serve the air-conditioning of the building including the offices and the technical spaces. No secondary chilled water pumps shall be utilized for the building since the pressure of the chiller primary pumps should suffice. The AHU’s and FCU’s shall have two-way valve control with three-way valve control at the end of the piping branches to maintain a minimum flow. The chillers plant floor will be cooled with chilled water fan coil units installed exposed and controlled as a group with remote sensors that modulate a common three-way valve. Outside ventilation air for the plant floor will be cooled with a chilled water AHU located in the first floor. The plant room fresh air AHU shall have an energy recovery system. The AHU shall have an air to air heat exchange section and an exhaust fan section besides the supply fan section. Air conditioning of each office will be achieved with FCUs or small AHUs with ducted air distribution. Fresh air supply will be extended to each unit through a common fresh air fan with filter located on the roof of the office block. In the offices block foul air of bathroom and pantries will be exhausted into adjoining shaft and pulled up by common exhaust fan. Fire and smoke dampers will be provided at each air exhaust point into the vertical shaft or when crossing the fire wall to control fire spread. Electrical rooms shall be air-conditioned with air handling units located in the first floor. The fresh air and exhaust of the chiller area and the MV rooms will be taken in and discharged from façade louvers on the first floor level. The pumps room in the basement shall be air-conditioned by fan coil units. AHU’s shall be interlocked to the fire alarm system such that they shut off upon fire detection in the relevant spaces. Also, all ducts crossing fire rated zones shall have fire dampers on them.

Plumbing Codes and Standards The plumbing system including potable water, non-potable water, sanitary waste, and storm sewer will be designed in accordance with the applicable industry standards and shall conform to the provisions of the latest issue of applicable U.S.A. codes and standards including but not limited to the following: •


•

Uniform Plumbing Code (UPC)

•

American Society of Plumbing Engineers (ASPE)


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•


•


•

Applicable Local Codes and Standards

•

Other standards listed in the Tender Documents

Water Supply Network Plumbing system includes water closets with ablution hoses, urinals, lavatories, sinks, showers, and hose bibbs. Potable water also provides make-up for the chilled water system. Non-potable water is provided for cooling tower make-up water. The building shall be supplied from the municipality, from sea water pumping station and from a TSE plant. Concrete tanks shall be provided in the basement level of the building for water storage. One tank shall be used for fire water storage and one for raw water storage and a third for permeate water storage. A pumping room in the basement shall accommodate the fire and water pumps. The offices toilets and services shall be supplied by gravity from polyethylene tanks located on the roof above them. The tanks shall be supplied from the municipality water. A booster set for the building services and hose bibs shall be used in the basement pump room. The municipality water shall supply the fire tank and the offices tanks and the cooling towers sumps. Basement storage tank will be sized for: •

Two-hour storage for the RO water.

•

Fire reserve for fire fighting: 90 minutes fire pump operation. (approx. 200m3).

Offices Roof water tank will be sized for a minimum of one day. A Reverse Osmosis system shall treat raw water (sea water) and discharge it into the permeate water tank. A booster set shall supply make-up water from the permeate water tank to the cooling tower sump on roof. TSE water shall be used for cooling tower make-up water. Sizing Criteria: Domestic water pipes shall be sized based on the plumbing fixture method with a maximum pressure drop of 10 percent and maximum velocity of 2 m/sec.


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Hot Water Production: Domestic hot water will be individual for every toilet and pantry through electric water heaters. Hot water demand will be calculated by ASHRAE Hot Water Demand Method. Waste Water Drainage Soil and waste water shall be collected from the building through riser to the external network manholes. Chillers area shall be provided with grated gutters and connected to the sewer system. A Floor drain is installed in each toilet and pantry block. All drainage pipes inside the toilets or pantries are exposed under slab. All the drainage piping, in risers or in horizontal runs shall be Cast Iron. An underground drainage system is provided at the basement level for water tanks drainage and pumping room drainage as well as water treatment system back wash. A sump pit with duplex submersible sump pumps set shall be provided in the bottom of the basement floor to serve the water tanks and pump room in the basement. The pipes shall run at 1 percent slope. Concrete manholes drains, with grated cover and sufficient size and depth are collecting all the water infiltration or water flushing. WC’s throughout the project are with flush tanks. The cooling towers over flow and blow out shall be drained down to the sewer network with Black Steel pipe risers. The sump drainage shall be controlled to drain the volume over 24 hours. The blow out and sump drainage lines shall pass in the first floor ceiling in the AHU area and then through a shaft in the chillers area. The cooling tower design blow down water quantity is around 700 gpm. Waste Water Drainage Independent rain water network is provided throughout the project. Storm water will be collected through roof drains and conveyed through risers using cast iron pipes down to the external storm manhole. Storm water pipes will be sized as per UPC based on 50 mm /hr intensity. The rain water risers will be passed on the peripheral columns and walls cladding to avoid passing in technical or electrical areas. Rain water inlets will be provided to all paved areas, balconies, and planters. The storm water piping and sundries (roof drains, etc.), shall be in cast iron.


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Compressed Air Standards and Codes Compressed air systems will be designed in accordance with codes and standards of the American Society of Mechanical Engineers (ASME) and standards of the American Society for Testing and Materials (ASTM). Service Air The service air system will be designed for 16 CFM operating at a pressure of 100 psig.

Fire Suppression System Codes and Standards The fire suppression system including potable water, non-potable water, sanitary waste, and storm sewer will be designed in accordance with the applicable industry standards and shall conform to the provisions of the latest issue of applicable U.S.A. codes and standards including but not limited to the following: •


•

National Fire Protection Association Codes and Standards (NFPA) or local equivalent

•

The local Fire Department / Civil Defense fire safety requirements, if available, are needed, whether for fire suppression, fire alarm or for requirements from other systems (HVAC, electrical power,…)

•

Other Applicable Local Codes and Standards

•

Other Standards Listed in the Tender Documents

Fire Suppression System A combined fire sprinkler and standpipes system will be provided throughout the building and the podiums and the basements car park areas. The system will largely comply to NFPA 13 and 14. Dedicated fire pumps, supplied conforming to NFPA 20 and installed at the basement, will pressurize the wet system of sprinklers and fire hoses. One electric and one diesel fire pump and one jockey pump will be located in the basement floor to meet the pressure/flow requirements of NFPA for the systems listed above. The capacity of the fire water tank in the basement shall be based on 90 minute operation. The estimated fire pump capacity is 750 gpm. Alarm zone valves are installed on the fire sprinkler system. Each floor branch shall have a zone control valve. Fire hose reels in cabinets with firemen hose connection through wet riser pipes. A Wet riser and landing valves will be provided in each stair with landing valves at each floor.


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A Siamese connection at the building entrance shall connect to the system. Fire Hose Cabinets with 1 1/2-inch hose racks and 2 1/2-inch fire department valves and portable fire extinguishers shall be installed such that all the areas are covered. Portable CO2 extinguishers will be provided for electrical and telecom (or light current) rooms. The plant floor will have a wet pipe sprinkler system with the design density requirements for an Ordinary Hazard Group 1 Occupancy. The electrical areas will have a deluge system with the design density requirements for an Ordinary Hazard Group 1 Occupancy. The transformer areas will have a wet pipe sprinkler system with the design density requirements for an Extra Hazard Group 1 Occupancy. The Control Room and the telecom room shall be provided with a common FM-200 Fire Suppression System. Table 5-1 Main Mechanical Services Schedule Area

Dry-Bulb Temp (°C)

Relative Humidity (%)

AC Method

Ventilation

Fire Suppression

Wet Sprinkler

Chiller Area (GF)

28-30

N/A

FCU

Tempered Fresh Air (2.6 L/S/M2) Emergency Refrigerant Ventilation

Electrical Room (1F)

28-30

N/A

AHU

None

Deluge System

HVAC Area (1F)

28-30

N/A

AHU

2.6 L/S/M2

Wet Sprinkler

Control Room (Mezz)

23-25

50 +/-5%

FCU

8 LPS per Person

FM-200

Telecomm Room

23-25

50 +/-5%

FCU

8 LPS per Person

FM-200

Senior Staff Office

23-25

50 +/-5%

FCU

8 LPS per Person

Wet Sprinkler

General Office (1F)

23-25

50 +/-5%

FCU

8 LPS per Person

Wet Sprinkler

Mech. Workshop

23-25

50 +/-5%

FCU

8 LPS per Person

Wet Sprinkler

Toilets

N. C.

N. C.

None

10 AC/Hr

None

Pump Room (Basement)

28-30

N. C.

FCU

2 AC/Hr

Wet Sprinkler

Transformer Room

5°C Above Ambient

N. C.

Fans

As Required

Deluge System


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Section 6

Electrical Design Statement

General This section of the Design Intent Report includes the narrative description of the plant electrical systems including distribution, motor control, general building power, building lighting, and extra low voltage systems for the Integrated District Cooling Plant (IDCP) at The Pearl, Qatar. Discussions between the Owner, Qatar Cool, PMC, the Contractor, C.A.T. International (CAT), and the Design-Build Engineer, Stanley Consultants are detailed in Exhibit A – Project Correspondence.

Compliance Statement The Electrical design will comply with all portions of the Tender Documents prepared for Qatar Cool and issued by DAR during the tender phase. These documents include the general requirements, tender specifications, room data sheets, tender drawings, and the appropriate addendums and tender circulars issued for clarification, except as noted below: •

Plant Arrangement: The IDCP will be based upon the plant arrangement from the Alternate 2 bid proposed by CAT and accepted by Qatar Cool prior to contract award.

•

Any references to changes that have been agreed upon and not referenced in the above listed documents including, but not limited to, thermal storage, secondary pumps, 3.3-kV CT Fans, 3.3-kV VFDs, etc., will be disregarded.

•

Use of the terms High Voltage, Medium Voltage, Low Voltage and their respective abbreviations HV, MV, and LV will be minimized to avoid confusion. Voltage levels will be defined per the Electrical Works Tender section A.4 Power Supply Characteristics.

•

Ratings of electrical equipment will be based on detailed design calculations based in part on information received from the Electrical Utility and Primary Substation and Infrastructure Contractors.

Q06024-IDCP-RPT-EL-001-REV 3

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•

Electrical Power Distribution

•

Electrical Power Supply, Protection and Distribution

•

Emergency Engine Generators

•

Power Distribution Boards

•

Power Factors Correction

•

Uninterruptible Power Supply UPS

•

Internal and External Lighting

•

Cabling and Wiring

•

Raceways, Cables Trays/Ladders and Trunking

•

Wiring Devices

•

Earthing Network

•

Lightning Network

Extra Low Voltage •

Fire Alarm System

•

Voice and Data Systems

•

Closed Circuit Television

•

Security Access Control

Applicable Codes and Standards and Basic Design Criteria The electrical products and installations will comply in general to the Tender Documents, to the Local regulations and to the British Standards and to the International Electrotechnical Commission IEC. However, for life safety related subjects, the National Fire Protection Association (NFPA) regulations will be adopted. The concept of the electrical installations will be based on the main objectives as summarized below: •

To comply with the applicable standards.

•

To achieve reliability and durability of systems and components.

•

To implement safety measures for the protection of people and equipment.

While achieving the deign objectives, other important factors will be carefully considered as follows: •

Efficiency and Energy Conservation

•

Coordinated Design Elements

•

Simplifying of Systems Operation and Maintenance


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Ambient Conditions All the electrical installations and equipment will be specified and de-rated for continuous and trouble-free operation in the ambient conditions of Doha as per the Tender Documents requirements. The equipment, apparatus, material and accessories will be specified to be corrosion proof, and UV stabilized if used outdoors.

Electrical Power Distribution Overall System Description The new plant will be served from three 66-kV radial feeds from the local utility that will feed three 66 k/11 kV, 50/60 MVA high-voltage transformers. The 66-kV feeders and high-voltage transformers will be provided by others. The electrical system consists of three 11-kV switchgear line-ups (one per transformer) that might be coupled if required during coordination design, twenty 11 kV/3.3 kV, 6.6/8.8 MVA medium-voltage transformers, twenty 3.3-kV motor control centers, six 11 kV/415 V, 1.6 MVA low-voltage transformers, 415-volt motor control centers, and 415-volt main distribution boards. Building power will be distributed at 415/240 volt, 50Hz, 3 phase and 4 wire, with separate neutral and protective conductor TN-S configuration. The power factor of the plant will be maintained at 0.9. The necessary capacitor banks and switching control elements will be carefully studied and implemented on the 3.3 kV and 415-V level switchgears to match with motor loads in particular and prevent any capacitive load. Motor starters will consist of ninety-two 3.3-kV soft start starters for chiller motors, twentyfour 3.3-kV soft start starters for condenser water pumps, twenty-three 3.3-kV soft start starters for chilled water pumps, twenty-four 415-volt Variable Frequency Drives (VFD) for cooling tower motors, and miscellaneous 415-volt starters for building auxiliaries and the Reverse Osmosis (RO) system. Other miscellaneous electrical equipment consists of two emergency diesel generators, two automatic transfer switches (ATS), an uninterruptible power source, miscellaneous distribution boards and a grounding grid. The two emergency diesel generators are required to serve the Supervisory Control and Data Acquisition (SCADA) system, fire pump, lighting, and ventilation requirements of the chemical storage area. The generator will be sized to carry these loads and any other auxiliary loads required. The emergency loads will be transferred via an automatic transfer switch. In general, the electrical design for the plant will utilize cable tray to distribute cables throughout the plant, and where multiple cables run to the same location. Conduit and wire systems will be used where it is not feasible to use cable tray.


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Specifications and design drawings will be provided as part of the design package. The documents will be coordinated with other disciplines to reduce the possibility of conflicts between trades during construction. Sufficient detail will be furnished to convey the scope of work intended to ensure the Contractors ability to build the electrical work, within budget, and while meeting the project schedule and avoiding costly change orders.

Emergency Engine Generators Two emergency diesel engine generators, with synchronizing and paralleling means, will be installed. Each generator will cater for the entire emergency load separately. It will have 84-hour rated bulk fuel tanks with daily tanks and will feed the following essential loads: •

Emergency Lighting: Maintained and non-maintained type.

•

All the mechanical equipment meant for life safety, such as pressurizing units, smoke exhausts, elevators and the like.

•

Fire alarm, CCTV, access control, SCADA mains, via UPS and the like.

•

Fire pump, jockey pump.

•

Basement drainage lifting pump.

Diesel generator rooms will be treated against the noise in such a way to obtain acceptable noise criteria value.

415/240-Volt Distribution Network Uninterruptible power Supply UPS Uninterruptible power supply unit will be provided for the supply of the SCADA equipment, instrumentation and control systems, with 100 percent redundancy and with maintenance free sealed lead acid battery ensuring 30-minute back up at full load in case of total power failure. The UPS unit will be provided with static bypass switch for economical mode operation and with a manual bypass switch for maintenance mode. Minimum harmonic distortion values will be adopted, with capabilities to switch to the gensets power feed without falling outside the permissible limits. Lighting and Emergency Lighting The arrangement, type and color of the lighting fixtures will be selected to match the specific area requirements and as per the schedules of the tender documents. The lighting layout will be coordinated with the ceiling grid and with other ceiling installations. Lamps will be specified with high power factor control gears in public and private areas Lighting levels will be in accordance with CIBSE recommendations. Refer to Exhibit C for details of room lighting type, level, and switching mode. Lighting control panels with control means will be distributed and will be controlled from the supervisory room. Offices, stores and the like will be controlled from local switches.


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Emergency lighting will comply to NFPA 101 requirements and will be provided at each area in order to ensure the minimum lighting level in case of mains power cut. The emergency lighting will be provided by means of self contained battery units built-in the inside of the relevant lighting fixture with one-hour autonomous operation. Boards Boards will comply to IEC439-1 and with local regulations. All boards will be type tested with color matching the surround. All boards and panels will be labeled, ferruled and will be provided with a laminated distribution schedule sheet mounted inside the main door frame. All indoor boards and panels will be cooled or ventilated in order to ensure proper components’ heat dissipation. Spare and spaces will be ensured inside each enclosure. The main distribution board (MDB) will be located in the central electrical room. Each outgoing feeder will supply a secondary board through armored cables. The sub main distribution boards (SMDB) will be located in secondary electrical rooms and/or closets. The mechanical rooms and other miscellaneous HVAC and mechanical equipment will be fed through motor control panels or motor control centers and through built-in motor starters as required. Feeder pillars will be reserved for the external areas. The final branch circuit panel boards will be of the DIN chassis assembly type. These panels will be located as much as possible nearby the final branch loads, while ensuring proper accessibility and maintainability. Separate distribution boards will be provided for lighting and sockets, HVAC and outdoor usage. Circuit Breakers, Residual Current Interrupters, Contactors and Disconnect Switches ACBs air circuit breakers will be provided with display units indicating beaker status, load faults nature (long time, short time, instantaneous and earth fault), each with counter. ACBs will be installed at the upstream of MDBs and MCCs. MCCBs having a frame larger than 250A will have an electronic trip release with LSI unit; long time trip with rating and time adjustable, short time trip with rating and time adjustable and instantaneous trip with rating adjustable. The distribution and selection of the breakers will take into account the short circuit discrimination, redundancy and reliability. The circuits will be protected against the earth leakage with the aid of earth leakage interrupters rated as follows: • Up To Four Circuits of Lighting

30 mA

• Up To Four Circuits of Sockets

30 mA

• Fan Coil Unit

100 mA

• Condensing or Package Unit

100-300 mA

• Each Water Heater

30 mA


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• Washing Equipment

30 mA

• Each Motor other than HVAC

30-300 mA

Contactors will be used for general HAVC, motors and lighting control. The Contactors will comply to IEC 947-5 and will be at least rated Category 3 for inductive loads. Disconnect switches will be used wherever a load is supplied from an unseen panel and will be rated AC23 for inductive load. Cables and Wires Wires and cables will comply to IEC Standards. Current carrying capacities will be determined in accordance with the regulations for specified and expected conditions of installations at the maximum ambient temperatures. All cables will be multicore, copper conductors and steel wire armored with XLPE insulation 90°C rated, with PVC sheathing. All wires will be unarmored, 70°C rated, PVC sheathed. Only earthing wires will be green/yellow striped and PVC insulated. Life safety cables for fire alarm, fire fighting, maintained exit lighting, fire pump and other life safety equipment will be fire rated to IEC 60331 and IEC 60332. Raceways Heavy gauge PVC conduits will be used in embedded locations while EMT galvanized conduits, trunking, trays and /or ladders will be used for exposed conditions. Flexible stainless steel conduits will be used for motors connections and for vibrating equipment. EMT conduits will be installed in exposed high moisture and humid locations. Raceway installations will be avoided in inaccessible areas. Size of raceways will be in accordance with the IEE regulations. A minimum of 40 percent spare will be provided for conduits and trunking, and 20 percent for trays and ladders. Electrical outlets for remote electronic equipment such as fire alarm panel, CCTV camera, motion detector and the like will be spur-fused type. Earthing Network Earthing system will consist of TN-S scheme as per the IEE regulations. Thus, a five wire separate network will be distributed all over. The main earth electrode will consist of earth rods installed at equidistant points nearby the plant perimeter and connected up to the electrical room. The earthing system will ensure proper tripping of 415V distribution breakers in case of phase to earth faults, and will be designed to trip the earth leakage breakers in case of phase to contact faults.


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Main earth bars will be distributed all over the plant with bonding, equipotential and extraneous conductors connected to machines, grids and exposed metallic frames respectively. Separate clean earth for extra low-voltage systems such as SCADA, CCTV, access control, fire alarm and the like will be provided and will be totally segregated from the power earthing equipotential effects, and will be formed of a separate grid with inspection means. Lightning Protection The complete plant will be protected against lightning in accordance with a BS6651 compliant lightning protection system consisting of: • Roof conductor grids of 20m by 10m, with bonding to the exposed metallic equipment. Protection will not cover the heights of the cooling towers as long as the cooling towers are of fiber type. • Down conductors, each with a test link at accessible and non-harmful height. • Lightning ring electrode with lightning earth rods.

Extra Low Voltage Fire Alarm System The facility will be provided with a Fire Alarm System covering the entire area. The system will be an analog addressable system consisting of automatic fire detectors, fire initiators and annunciation. The system design and installations will comply with the NFPA72 requirements. All cabling will be fire rated and will be Class A configuration. Life safety cables for fire alarm, fire fighting, maintained exit lighting, fire pump and other life safety equipment will be fire rated to IEC 60331 and IEC 60332 and will be red color coded. The systems will comprise the main fire alarm cabinet, system console with PC fire station and printer, addressable automatic detectors consisting of smoke, heat and rate of rise type, manual fire stations and alarm devices consisting of bells, sounders as well as provision for direct connection to the local Fire Station by direct telephone line. The fire alarm system shall also seize control of the life safety equipment in case of fire and shall control it according to the cause and effect matrix that will be elaborated for the Plant. Such control will be ensured via analog addressable relay control modules with line monitor modules for monitoring and reporting. It is worth mentioning herein that for the chiller hall, there is a 9.1m height limitation by NFPA for the installation of smoke detectors, which is not in line with the chiller hall height that is 10.3m. Therefore, the beam detector is the recommended solution. However, due to ceiling congestion and crane mobility at the chiller hall, which will create false alarms for the beam detectors, we will install suspended smoke detectors down to 9.1m. Moreover, in order to cover the buffer between the 9.1m and the ceiling height, we will reduce the spacing of detectors to 12 meters.


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Voice and Data System All the installations will be designed and installed as per Q-Tel regulations. The voice and data system will consist of structural cabling and connections distributed all over the plant and at points described in Exhibit C of this report. The horizontal distribution will consist of Category 6 unshielded twisted pair cabling, with RJ45 outlets. The vertical and backbone cabling will consist of multipair cables for voice and multimode fiber-optic cable for the data. The main voice and data cabinets will consist of wall or free standing 19-inch cabinets consisting of data patch panels, copper and fiber-optic patch panels, horizontal cross connect, active switch and mains power supply. An EPABX and MDF will be installed at the telecom room of the Administration Building. The EPABX and MDF will be designed and sized to cater for the trunks and extensions with 10 percent spare capacity. All EPABX, MDFs, patch panels and the like will be designed to be expandable and scalable. The work will include provisions for the connection with the external services. Q-Tel GSM Station A dedicated room for Q-Tel GSM Station will be provided and will be equipped with the requirements of Q-Tel in terms of power, ventilation, cooling and the like. Room shall be 3M x 3M minimum and be air-conditioned. Work shall be done in accordance with Q-Tel requirements and subject to their approval. The room temperature will be maintained at 20-25°C. The room will be provided with separate clean earth for the use of Q-Tel. Closed Circuit Television System (CCTV) The system is meant to ensure continuous monitoring and surveillance of the plant entries, perimeter and gates, lobbies and selected areas as per the attached Exhibit C. Cameras will be colored CCD, fixed or PTZ (pan/tilt/zoom) type as per the schedule. The system will be software enabled, with video matrix switching with enough capacity, scalable and expandable. Color monitors and operator consoles with intelligent keyboards will be installed in the control room inside dedicated cabinets, along with select and shoot panel and with digital video recorders (software enabled) with continuous recording for one week and with automatic back up. The system will also ensure the communication with other systems such as the fire alarm and security access control systems via integrated communication ports.


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Stanley Consultants

Access Control and Door Status System The system shall be of modular programmable type, utilizing LAN and RS485 network. The system shall provide necessary access control for critical locations and monitoring of all doors as described in Exhibit C. The system shall comprise the following components: • System server and converters, control panel complete with power supply and back-up batteries. • Operator work station Pentium IV, 2.6 GHz, 40 GB H.D., 512 MB RAM, 24xCD– Rom Drive and 3.5-inch floppy drive. • Magnetic contact and micro switch for each door. • Proximity card readers of the intelligent type with built in tamper switch connection to security control room. Access control validation shall be based on time of day, day of week, holiday scheduling, etc. Magnetic contacts shall be used to detect open/closed status and micro-switches shall be used to detect locked status. The system shall be interfaced with Fire Alarm system.


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Section 7

Control System Design Statement

General This section of the Design Intent Report includes the narrative description of the control system for the Integrated District Cooling Plant at The Pearl Project. Discussions between the Owner, Qatar Cool, PMC, the Contractor, C.A.T. International (CAT), and the Design-Build Engineer, Stanley Consultants are detailed in Exhibit A – Project Correspondence.

Compliance Statement The Control System design will comply with all portions of the Tender Documents prepared for Qatar Cool and issued by DAR during the tender phase. These documents include the general requirements, tender specifications, room data sheets, tender drawings, and the appropriate addendums and tender circulars issued for clarification, except as noted below: • Plant Arrangement: The IDCP will be based upon the plant arrangement from the Alternate 2 bid proposed by CAT and accepted by Qatar Cool prior to contract award. • 6.1.2.1 PLC shall be installed in PLC/UPS Room on first floor. • 6.10.6 states that all motor controls including VFD will be done through the MCC and SCADA while 6.1.11.1.(a) states not all control loops or motor controls will reside in the SCADA environment. Motor control, including VFD, will be done through the MCC and SCADA. Packaged system controllers will provide control for the motors included within the respective package. SCADA will be configured to monitor and log run status and run time of motors controlled by package system controllers. • 6.1.11.3.(iv) No secondary pumps are included. • 6.1.11.3.(iv) Soft starter for chillers will be controlled by hard wired stop/stop signals from each respective chiller control panel. SCADA will monitor and log the run status of each chiller motor.


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• 6.1.11.3(b).(vi) Chilled water supply temperature setpoint will be hard wired from SCADA to each chiller control panel. • 6.1.11.3(b).(ix) Chiller start/stop sequence will be controlled by differential pressure, chilled water supply temperature, and chiller power as described in the “Chilled Water System” section below. • 6.1.11.3(b).(xi) Ice storage is not included. • 6.1.11.3(b).(xii) Thermal energy storage is not included. • 6.1.11.3(b).(xxiii) Graphical screens showing chiller pairs for each distribution loop shall be based on Process and Instrumentation Diagrams. • 6.1.11.3(n) Secondary chilled water distribution pumps are not included. • 6.1.11.3(p).(xiv) Vibration switch and gear box low oil switch shall be hardwired to the associated VFD to stop the cooling tower fan if vibration is high or gear box oil is low. • 6.1.12.1 VAC will be controlled by DDC controllers with digital communication for integration with SCADA. • 6.2.1.2.(b) Communication protocol(s) will be those required for integration of main plant field instruments and control systems on packaged systems.

Control Philosophy The control system will be a PLC-based Supervisory Control and Data Acquisition (SCADA) system designed to centralize the monitoring and control of the production and distribution of chilled water in the District Cooling Plant (DCP), Heat Exchanger Buildings (HEX), and Energy Transfer Stations (ETS). A SCADA system programmable logic controller (PLC) will perform monitoring and control functions within the DCP. A local PLC mounted at each HEX or ETS location will perform monitoring and control functions for that HEX or ETS and utilize Ethernet communication for communication with the SCADA system. Operators will monitor and control the DCP, HEX, and ETS processes through SCADA system operator workstations configured with dynamic graphics for each process. Alarm summaries, selective input/output trends, and historical data will be stored on application, management, and information servers. An engineering workstation will provide SCADA system application and development capability. Open communication protocols will allow integration with the Island Operation Center and National Operation Center. Packaged equipment control will be performed by a local controller mounted in a local control panel. Each packaged equipment controller will be integrated into the SCADA system through Modbus or other approved communication protocol.


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Chiller pairs will include a local control panel with HMI that will provide manual and automatic operation of the chiller pairs for starting, operation, normal shutdown, and emergency shutdown of the chiller pair, and safety protection interlocks for the chiller pair. The chiller control panels will be integrated into the SCADA system utilizing Modbus communication protocol. Local chiller control panel will provide the following control functionality: • Support local and remote control modes by means of Owner's control system. • Maintain leaving water temperature within 0.5ºF of setpoint. • Maintain internal refrigerant processes and chiller equipment within acceptable operating bounds through operating range of 25-100 percent of capacity. • Limit chiller electric demand to setpoint within range of 40 percent to 100 percent. • Incorporate protective controls with local alarm status and reset capability for high oil temperature, low differential oil pressure, high and low refrigerant pressure, low condenser water and chilled water differential pressure, chilled water low temperature, and condenser water high and low temperature. • Have demand limit of 10 percent to 100 percent FLA based on setpoint. Local Operation: • “Local-Off-Remote” mode selections on HMI: “Local,” start initiated at chiller; “Remote,” start initiated from Owner’s control system. • Emergency Stop Pushbutton. • Provide local LCD or LED displays for HMI. • Local Alarms: - Low Chilled Water Differential Pressure - Low Condenser Water Pressure - Low Condenser Water Temperature - High Oil Temperature - Low Oil Differential Pressure - High Refrigerant Pressure - Low Refrigerant Pressure - Low Refrigerant Temperature - Starter Fault • Alarm Horn, 100 dB minimum. • Horn Silence Switch.


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Hardware and software for Modbus communication interface to communicate with Owner’s control system for remote control, monitoring, trending, system diagnostic, and troubleshooting. • Preliminary I/O list shall include, but not be limited to the following points. Vendor to add additional points as necessary for proper remote operation and control. Final list is subject to Owner’s review and approval. - Discrete Outputs: • Chiller Run Status • Chiller Alarm Status • Refrigerant Leak Detection • Mode Selector Switch In “Local” • Mode Selector Switch In “Remote” • Compressor Started Fault • Low Oil Pressure • High Oil Pressure • Purge Pump Run Status • Low Oil Level Status - Analog Outputs: • Leaving Chilled Water Temperature Setpoint • Demand Limit Setpoint • Leaving Chilled Water Temperature • Entering Chilled Water Temperature • Chilled Water Differential Pressure • Leaving Condenser Water Temperature • Entering Condenser Water Temperature • Condenser Water Differential Pressure • Evaporator Refrigerant Temperature • Condenser Refrigerant Temperature • Compressor Discharge Refrigerant Temperature • Evaporator Refrigerant Pressure • Evaporator Differential Pressure • Condenser Refrigerant Pressure • Oil Temperature • Oil Pressure


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Stanley Consultants

• Oil Differential Pressure • Actual Guide Vane Pressure • Oil Sump Differential Pressure • Compressor Thrust Bearing Temperature • Inboard Motor Bearing Temperature • Outboard Motor Bearing Temperature • Inboard Compressor Bearing Temperature • Outboard Compressor Bearing Temperature • Motor Amperes • Demand kw HEX and ETS control will be performed at each remote location by a local PLC with HMI. The SCADA system will provide supervisory control data to each HEX or ETS PLC and receive process data from the HEX or ETS PLC through Ethernet communication. Digital communication connections will utilize UTP copper or fiber-optic media depending on the distance between each communicating device. Chilled Water System The chilled water system will employ a direct primary pumping scheme with constant speed pumps. Each chilled water pump is dedicated to a chiller pair. Chilled water pump suction and chilled water supply discharge piping from each chiller will connect to common headers. When operating in Automatic Mode, the SCADA system will start and stop chiller pairs based on the following: •

When the sum of the plant energy meter and plant HVAC energy meter indicates that total demand increases to full capacity of the currently operating chiller pair(s), the main plant PLC shall start the next chiller in the operator selected pre-defined starting sequence that has the “AUTO” mode selected and one of the following occurs: - Differential pressure between the chilled water supply header and chilled water return header increases to or above the field adjustable setpoint for a field adjustable time period. - Chilled water supply header temperature increases to or above ½°F (field adjustable) above the current leaving chilled water temperature setpoint for the currently operating chillers for a field adjustable time period. - Power input to the currently operating chiller pairs increases to or above the field adjustable setpoint.


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Stanley Consultants

Cooling Towers Each cooling tower cell has a dedicated condenser water pump and variable speed cooling tower fan. Condenser water supply and return headers allow the selection of any cooling tower cell to operate with any chiller pair. Cooling tower fan speed is controlled based on condenser water supply temperature. Low gear box oil and high fan vibration switches will de-energize and stop the fan should abnormal conditions be present. Make-Up Water System Each tower basin will be equipped with an automated make-up water system. The plant control system modulates the make-up water valve to maintain tower basin level. These valves are closed to prevent water flow to each tower when the operator has placed the tower out-of-service. The control system will monitor basin level and make-up water flow rate. Blowdown System The control system will monitor and control the blowdown rate based on condenser water conductivity. The operator will determine and adjust conductivity set point. Electrical System The SCADA system will provide hardwired inputs and outputs for motor control. Profibus DP communication protocol will allow the SCADA system to monitor, store and trend additional process information from starters, variable frequency drives, and multifunction relays.

Instrumentation Field Instruments DCP field instruments will communicate with the SCADA system utilizing Profibus DP communication protocol. ETS and HEX field instruments are 4 to 20-ma dc loop powered inputs and outputs.


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Stanley Consultants

Section 8

Utility Services Design Statement

General This section of the Design Intent Report includes the narrative description of the utility services and work for the Integrated District Cooling Plant (IDCP) at The Pearl, Qatar. Site survey data obtained during the course of this project will form the basis for the development of the grading and paving design. Discussions between the Owner, Qatar Cool, PMC, the Contractor, C.A.T. International (CAT), and the Design-Build Engineer, Stanley Consultants are detailed in Exhibit A – Project Correspondence.

Compliance Statement The Utility Services design will comply with all portions of the Tender Documents prepared for Qatar Cool and issued by DAR during the tender phase. These documents include the general requirements, tender specifications, tender drawings, and the appropriate addendums and tender circulars issued for clarification, except as noted below: • Plant Arrangement: The IDCP will be based upon the plant arrangement from the Alternate 2 bid proposed by CAT and accepted by Qatar Cool prior to contract award. • Site Layout: The latest revisions to the U-07 Plot limits will form the basis of the site layout, grading, and paving design.

Chilled Water Codes and Standards Chilled water piping, valves and fittings will be designed in accordance with American Society of Mechanical Engineers (ASME), American Water Works Association (AWWA), and American Society for Testing and Materials (ASTM).


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System Description Chilled water will be provided to the energy transfer stations and heat exchangers serving individual buildings through a distribution piping system. The design and construction for this project will include tying into the site distribution network at two locations from the new plant. Two 48-inch (1200 mm) chilled water lines (supply and return) will leave the IDCP at the west wall and connect to the distribution loop at the valve vault adjacent to the building. In addition, two 48-inch (1200 mm) chilled water lines (supply and return) will leave the IDCP at the east wall and connect to the distribution loop at the valve vault adjacent to the building. Buried chilled water piping will be constructed of pre-insulated direct-buried carbon steel pipe system in accordance with Section 60, Part 2 of the Tender Specifications. Installation of the proposed chilled water lines will require coordination with other utilities in the area. Permitting will be obtained for the established corridor to route the chilled water lines.

Potable Water Codes and Standards Potable water piping, valves, and fittings will be in accordance with American Water Works Association (AWWA), and American Society for Testing and Materials (ASTM). System Description Potable water service for the IDCP will be connected to the island distribution system and coordinated with the infrastructure contractor. Buried potable water lines will match the piping system used by the infrastructure contractor.

Sanitary Sewer Codes and Standards Sanitary sewer piping, valves, and fittings will be designed in accordance with American Water Works Association (AWWA) and American Society for Testing and Materials (ASTM). System Description Sanitary sewer service for the IDCP will be connected to the island distribution system and coordinated with the infrastructure contractor. Buried sanitary sewer lines will be constructed of cast iron, in accordance with Section 60, part 2 of the Tender Specifications.

Storm Sewer Codes and Standards Storm sewer piping, valves, and fittings will be designed in accordance with American Water Works Association (AWWA) and American Society for Testing and Materials (ASTM).


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Stanley Consultants

System Description Storm sewer service for the IDCP will be connected to the island distribution system and coordinated with the infrastructure contractor. Buried storm sewer lines will be constructed of cast iron, in accordance with Section 60, part 2 of the Tender Specifications.


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Section 9

Maintenance and Accessibility

General This section of the Design Intent Report includes the narrative description of the maintenance and accessibility for the Integrated District Cooling Plant (IDCP) at The Pearl, Qatar. Discussions between the Owner, Qatar Cool, PMC, the Contractor, C.A.T. International (CAT), and the Design-Build Engineer, Stanley Consultants are detailed in Exhibit A – Project Correspondence.

Compliance Statement The maintenance and accessibility within the plant will comply with all portions of the Tender Documents prepared for Qatar Cool and issued by DAR during the tender phase. These documents include the general requirements, tender specifications, tender drawings, and the appropriate addendums and tender circulars issued for clarification, except as noted below: • Plant Arrangement: The IDCP will be based upon the plant arrangement from the Alternate 2 bid proposed by CAT and accepted by Qatar Cool prior to contract award.

Maintenance and Accessibility Mechanical equipment will be installed for easy maintenance and service access. The design will allow adequate space to safely and efficiently inspect, maintain, repair, remove and replace equipment and components. Mechanical and electrical equipment will be installed in such a manner that it will not require temporary removal of a fixed building component, another piece of equipment, or unrelated piping, ductwork or electrical raceway so as to remove the equipment piece in question.


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A dedicated access aisle is located in the center of the plant to allow for future removal and replacement of individual chillers. This access aisle allows for clean access for operators to receive deliveries and carry out normal operations and maintenance functions within the plant. The access aisle is wide enough to allow sufficient tube pull space for the chillers. This will provide a means for cleaning and replacing the chiller refrigerant evaporator and refrigerant condenser tubes. Four traveling cranes will be included within the plant. These cranes will allow for the removal of equipment components such as pump motors and chiller compressors. Sufficient clearance has been provided for the removal of equipment using the traveling cranes without disturbing other unaffected equipment and piping. Equipment and/or components that are handled by the traveling cranes will be transported to the center of the plant between Column Rows H and J. The component in question can then be lowered to a pallet or skid at the floor level. The pallet or skid can then be moved from this location using a forklift or pallet jack. The forklift or pallet jack can be maneuvered from this location down the main access aisle between Column Rows 7 and 9 to the main equipment access door at the south end of the plant. The largest anticipated load expected to be carried by the traveling crane will be the chiller compressors. According to manufacturer’s data, this equipment is anticipated to weigh 4,000 kg. A vertical equipment access shaft is provided at the center of the plant. The purpose of this shaft is to provide a means for installation and removal of equipment to and from the first floor as well as to the roof level. A traveling crane will be located on the roof deck to provide a means of servicing the condenser water pumps and cooling tower fan motors. This traveling crane will also be used to move equipment from the ground floor to the first floor (Electrical Equipment or R.O. components). The last major feature for maintenance and accessibility is the access hatch located at grade and outside of the IDCP. The purpose of this hatch is to provide a means of servicing the emergency generators, fire pumps, and miscellaneous R.O. pumps located in the basement.


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Project Execution Plan.pdf

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