B1 - Plant modification for COWS implementation
B1 - Plant modification for COWS implementation Commit project execution plan Tendering and contracting Execution of contracted modification M - Intermediate work progress check point Integration with COWS prototype subsystem Plug with COWS process M - Project execution plan ready D3 - Project execution plan
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What
This activity included all the tasks needed to modify the existing plant for COWS implementation, starting with the drafting of final project execution plant, tendering and contracting and execution of contracted modification and ending with integration with COWS prototype subsystem and plug with COWS process.
How/Methods
The overview of plant modification for COWS implementation starts with final project execution plan.
This activity consists of drafting the project execution plan based on the observations made by SEARIS on the definitive project draft. SEARIS is responsible for validation and approval of the project with the collaboration of the SEAAMB experts.
The activity terminates with the milestone ascertaining "Project execution plan ready", expected by 5/09/2013.
After the execution plan has been accepted, tenders will be held for the following items:
- supply of test equipment and process machinery
- outside assistance for the performance of special maintenance works on all sections of the sludge line
- primary digester
- secondary digester
- pre-thickeners
- post-thickeners
- gasometer
- torch
- dewatering chamber
- electrical cabinet
- air exhaust and treatment plant.
Construction of the building for pretreatment of the bio-waste will be entirely managed by Viareggio Patrimonio in coordination with the COWS project director, to ensure that the execution timing is consecutive and that the activities do not cause any negative interference.
This activity will terminate with the drafting of the contracts with all the winning bidders.
Tendering will follow the procedure foreseen by the Italian Code of Contracts, Legislative Decree no. 163 of April 12, 2006.
The project director will coordinate the works of the technical office to prepare the tender specifications from the technical standpoint, starting from the specifications established in the preliminary project.
The SEARIS and SEAAMB experts will prepare the specifications for every tender.
The specifications will consist of a schedule of duties with the following indications:
- the base tender amount
- the definitive project for the tender of the electrical system and tender for assigning the construction works, on which the outside experts will have to draw up the definitive and execution project plans
- detailed layouts indicating the position of the different machines and indication of the needs of the project.
The project director will provide to draft the technical report, indicating the function of the entire process of anaerobic co-digestion of sludge and OFMSW.
The technical report will also describe the requisites and functional performance of every section of the installation, with respect to the integrated system.
For the performance of these activities the collaboration of outside assistants will be used to draft the technical expert estimations so as to give the proper value to the works subject to special maintenance or works to be constructed.
The administrative/legal offices of SEARIS and SEAAMB will provide to complete the schedule of duties with all the procedural and legal aspects necessary, and to send all the required communications to the entities necessary, as well as announcing the tender.
Control of the correspondence with the requisites of the winning bidder and all the other formalities required by law will be done by SEAAMB, which will also draft the relative works or supply contract.
Completion of the definitive project operations must be made within a maximum of 120 working days from the signature of the contract, and control of the work by outside experts will be the direct responsibility of SEARIS.
The term is foreseen as 20/02/2014 and an Intermediate work progress check point is slated for 10/04/2014.
With the assignment of the contracts, the project proceeds to the activities of realization by the contractors (Execution of contracted amendment).
The works management and coordination for the safety of the worksite will be carried out by outside experts, but the project director and a team of 1 specialized expert and 5 specialized workers will follow the works of extraordinary maintenance on the existing installations directly.
The most critical points, and those which require the most intensive activity of the operating and technical personnel of SEARIS are the operations of plant stoppage, which concern:
- primary digester,
- secondary digester,
- gasometer,
- torch,
- dewatering chamber and pre- and post-thickeners
Works on these subsystems must be carried out in such a way as not to interfere with the function of the water line and treatment process.
In particular, it will be necessary to perform activities to ensure the safety of the various sections, each of which is connected to the preceding one.
It will be necessary to implement new work systems that make it possible to provide a temporary bypass of the sections undergoing work (also by laying new temporary pipelines and electrical connections, and reconfiguring the remote control devices for surveillance of the plant when it is not manned).
The progress of the works will be continuously monitored by the project director, with the help of the works director and assistant; he will communicate with the supervisory personnel and coordinate the different companies at work to ensure regular operation of the sludge line.
SEARIS is responsible for monitoring the work of the outside companies.
The SEAMB experts will perform controls and analyses of any critical situations that may arise. The administrative office of SEARIS shall report the progress of the works and, with the aid of that of SEAAMB will ascertain the requisites for making all payments.
SEARIS Spa will be responsible for ensuring that the payments correspond with the financial plan drafted.
Next step is the integration with COWS prototype subsystem.
Integration with the prototype subsystem of separation and pulping is part of the entire action of modification of the plant, but it is kept separate also from the planning standpoint because it concerns connection with the subsystem of mechanical pretreatment that is the prototype component of the project.
Construction of the subsystem will be affected by the final choice of the specific separation technology for which the prototype will be developed, i.e. the station hosting the separation and pulping equipment and its input.
For the organization of the work, this interface is treated with special attention because it must ensure that there is a good capacity of adaptation of the system to the separation station, which could require even major adjustments.
The integration concludes with the effective plug-in of the subsystem to the process and the startup and fine-tuning, as well as calibration, of the process.
Where
This action will mainly take place at plant site in Viareggio.
When
22/03/13-15/01/15
Execution of contracted works starts on 18/10/2013
Integration with prototype substation starts on 31/10/2014, plug-in of all process parts takes place in January 2015
Constraints and assumptions
- Constraints
- Construction of the building will be commissioned with a tender managed by Viareggio Patrimoni in respect of the timing foreseen for completion (ready by 10/4/2014)
- After starting the works on the processing lines, it will be essential to proceed without interruption, as temporary parts of the plant will be inserted.
- Execution must be completed on schedule in order to leave significant time for demonstration of running process.
- Assumptions
- Equipment supply and installation does not face unforeseen, blocking issues
- No disrupting organizational change will occur in suppliers organizations
- Turnover of key project resources is low.
- Delays on critical path may be handled by careful monitoring and control by project management. Buffer time allocated in planning is sufficient. Contracts include provisions for increasing allocated workforce if necessary.
Beneficiary responsible for implementation
P1-SEARIS
Expected results
The overall result of this action is the plant ready for hosting the new process, which means that all devices, lines and piping for including the secondary digester, the pre-treatment (separator) unit and CHP unit are in place. This action is performed simultaneously and in combination with the construction and installation of the separator subsystem. Outputs are:
- Awarded contracts
- services and works
- electrical cabling
- piping and ancillary works
- principal upgrading works (primary and secondary digester, pre- and post-thickeners, gasometer and torch, dewatering chamber)
- de-aeration and air filtering (turn-key project and works)
- Equipment supply contracts and accepted delivery
- 3 Compressors
- 1 Dynamic Thickener
- 1 Polyelectrolyte pre-processor
- 8 Pumps
- 1 System control and data acquisition (SCADA) system
- 1 Dewatering centrifuge
- 2 Cogeneration engines 650 KWh
- Laboratory equipment for routine insight measurements: 1 mass spectrophotometer, 1 pH meter, 1 lab centrifuge, 1 high precision lab oven (low temperature), 1 high precision lab oven (high temperature), 1 lab distillation apparatus
- Modifications of processing plant in compliance with acceptance criteria
- modified piping and controls of primary digester
- modified piping and controls of secondary digester
- modified piping and controls of pre-thickeners
- modified piping and controls of post-thickeners
- 1 gasometer revamped
- 1 flare torch revamped
- 1 dewatering chamber upgraded
- 1 power station for grid connection for surplus export installed
- 1 de-aeration and air filtering unit implemented
Indicators of progress
- Schedule and effort variance;
- actual vs. planned start/duration of tasks (if buffer time reserved for contingencies is to be used then remediation actions must be triggered);
- actual vs. planned resource use (15% work overload and 5% budget variance are thresholds for triggering remediation actions)
- Performance
- Delivery of compliant outputs:
- tender terms of reference and documents, contract documents
- Quality of delivered outputs: acceptance test documents for all contracts
Attached scheme of plant modification
