Modular Solutions & Off-site manufacturing for chilled water plants · 2019-12-29 · DDC Plant Main CHW Network Piping Branch & Plot Piping to suit 67% to 100% Load 34% to 66% Load

Modular Solutions & Off-site manufacturing forchilled water plants

Olivier BoshartBusiness Development Manager Modular Chiller PlantsDaikin [email protected]+971 54 307 4599

Presentation TitleModular Solutions & Off-site Manufacturing ForChilled Water Plants

• What is a Modular Plant

• History of Modular Construction

• Application, Driving Factors & Benefits

• Utilization of Modular Plants in District Cooling

Presentation Title

WHAT IS A MODULAR PLANT?

Presentation TitleWhat is a modular chiller plant?



Presentation Title

HISTORY

History of modular construction

Birth of Modular Construction

The first documented prefabricatedhome was created by a Londoncarpenter for his son, who was movingfrom England to Australia. He built aprefabricated house in pieces, thenshipped it to the Land Down Under foreasy assembly.

First Modular Chiller Plant

Pioneered in the United States for asmall commercial application.Subsequent usage of MCP were forIndustrial applications

First Modular Plant in Dubai

Provided for the Jumeirah Beach ResidenceProject. The project consisted of 12modules of 5000 TR

+900,000 TR in Middle‐East

Close to a million tons of coolingcapacity are provided using modularChiller plants, Mostly for the districtcooling sector1830s

1995

2005

2019

History of Daikin modular construction

• HydroKool Founded in 2006• Acquired by Daikin in 2010• Located In Phoenix, AZ• Over 200 MCP delivered• Primarily covering North America

History of Daikin modular construction

Factory Phoenix ‐ USA

Manufacturing Agreements with Local Companies in GCC

Since 2017

Daikin Dedicated Team to Modular Plants Construction based in Dubai.

Modular construction is a growing segment worldwide

Presentation TitleTypical applications with modular plants

District and Campus Cooling Turbine Inlet Air Chilling Data Centers

Airports, Military, Hospitals Oil & Gas Temporary Cooling

Presentation TitleWhat is driving Modular Construction?

Fast Track ProjectsSpeed to market

Limited SpaceRestricted Access

Custom Solutions

Quality & cost Control

Modularity / Scalability

Presentation TitleBenefits

Factory Assembled Enhanced quality control (Factory Quality Plan) Increased Productivity (repeatability) Lower Environmental Impact (waste, traffic, noise)

Single Source Responsibility From Design to Commissioning Optimized Performances

Flexibility Expandable, Moveable Shorter construction time & Simplified Installation

Create budget certainty The CHW process is now a product and not a project. Reduces unplanned work (non budgeted), exposure to variations or concessions Reduces engineering time and construction overheads

Presentation Title

DISTRICT COOLING

Presentation TitleDistrict Cooling Ideal Scenario

• All Plots are sold

• All buildings are going up

• Projects are on time

• Building Occupancy is Assured

• Cooling loads are accurate

• Cost per TR is low

Presentation TitleDistrict Cooling Nightmare (Reality) scenario

� New Developments rolled back or cancelled

� Some Sub-developers not building, others are, and they require Chilled Water

� Buildings far apart. Network piping still required

� Occupancy uncertain, even if buildings are built

� Cooling Loads are over estimated� Cost per TR of district cooling goes up� District Cooling plant is oversized or

delayed

Presentation TitleDistrict Cooling

Alternate ways forward

Presentation TitleTemporary modular plants for district cooling

• Usually 2 to 3 Plants

• Temporary but moving to permanent

• Located in vacant plots

• Use New or Existing chillers

• Basic Strip Foundation only required

• Easily Transportable

• Reusable again & again

Presentation TitleModular plants for district cooling

Contain all the Equipment required for Chilled water production

Chillers, pumps, Electrical, piping…

Presentation TitleModular plants for district cooling

Containerized or Trailer mounted Plants

for small capacities or emergencies

Presentation TitleAlternate ways forward

Hybrid Modular Chiller Plants

Presentation TitleHybrid Plants for District Cooling

Combination building, façade & Modular Chiller Plants

Building to house Electrical Equipment Control Room Storage Facilities..

Plant on Ground Level, no basement required

Qty of Modules Match Cooling Demand With or Without TES

Presentation TitleHybrid Plants for District Cooling

Phase 1: Initial Construction Phase 2: Capacity Increase. Year X

Presentation TitleHybrid Plants for District Cooling Example

Designed for 38,000 TR

Installed Capacity 19,000TR


WHY DON’T WE MAKE THE DISTRICT COOLING MODULAR?


DISTRIBUTED DISTRICT COOLING

Presentation TitleDistributed District Cooling

Phase 1Phase 2 Multiple Small Plants

Modular Chiller Plants Hybrid Type

Installed in Phases Plants are modular District cooling itself is modular

Use small size pipe network Optimized for Variable Primary Flow Interconnected for redundancy TES can be installed anywhere on

the network

Phase 3

Main CHW Network Piping

Branch & Plot Piping to suit

DDC Plant

Courtesy of Domiko

Distributed District Cooling Example



67% to 100% Load

34% to 66% Load

0% to 33% Load

DDC Plant



67% to 100% Load

34% to 66% Load

0% to 33% Load

DDC PlantMain CHW Network Piping


67% to 100% Load

34% to 66% Load

0% to 33% Load

DDC Plant



TES Tanks – Local or Satellite

DDC Plant

Hybrid Modular, this 6,000TR DDC plant forms part of final build out of 67,000TR.

Plant Room: 25m x 18mPlot Area : 40m x 45m

Includes sub station, make up water storage, and internal roads. Excludes TES and RO

Masdar Plant

Master plan calls for up to 8 plants of 6,000 TR plus 3 TES, installed as the development progresses.

Modular & DDC benefit: It is likely there will be less plants due to overstated plot loads.

Presentation TitleDistributed District Cooling Modular Plants

• Easily Integrated in Environment• Low Rise Buildings• Opportunities for smaller chillers with

latest technologies (Magnetic Bearing) • Wider choice in equipment such as Cooling

Tower• “Winter” Plants with High Efficiency

chillers• Lower Power Demand (utilities)


OFF‐SITE CONTRUCTIONFOR LARGE DC PLANTS

Presentation TitleOffsite

Presentation TitleOff-Site Manufacturing for Mega District Cooling

Pumps & PipingPumps & Piping ElectricalElectrical ChillersChillers


Individual Equipment Modules are reassembled at site to form a large plant


Chiller Module 3 Chiller Module 2 Chiller Module 1 Boiler Module

Presentation Title

OK…LAST SLIDE

Presentation TitleWhen to consider Modular Solutions?

Flexibility / ScalabilityShort TimelineSite Labor concernsSpace constraintsBudgets LimitationsRetrofit or custom solutions

THANK YOUFOR ATTENDING THE PRESENTATION

Please don´t forget to collect your CPD certificate during the event from the CPD collection area

Documents

Modular Solutions & Off-site manufacturing for chilled water plants · 2019-12-29 · DDC Plant Main CHW Network Piping Branch & Plot Piping to suit 67% to 100% Load 34% to 66% Load