The pre-feasibility study requested by QGPC concerns a smelter producing 25 kg aluminium ingots with an annual production capacity of 240,000-250,000 metric tonnes. The smelter will be based on ALUMINIUM PECHINEY AP 30 technology. It will be associated, on the same site, with a gas-fired power station capable of meeting the electric power requirements of the various units of the plant and of the related ancillary general services and utilities.
The smelter is to be built in UMN SAID, in the port area near other industrial units.
The pre-feasibility study is to be made in co-operation with QGPC. QGPC's approval shall be obtained by SOFRESID for all major assumptions adopted in the course of the study.
Summary of 500/600 items for the smelter and 200/250 items for the power plant.
The key information described above will be supported by a technical description in addition to the process description provided by AP for the aluminium smelter.
As regards the electric power station, EGT (European Gas Turbines) subsidiary of GEC Alsthom, acting as sub?contractor to SOFRESID, will provide a detailed technical description and a technical memorandum justifying the configuration adopted (number of turbines, unit power, etc...), to satisfy the various operating possibilities.
A project implementation schedule will complete the study.
3.1. SCOPE OF SERVICES
3.1.1. GENERAL
To undertake the pre-feasibility study, SOFRESID will involve a team of engineers specialised in the following fields:
· project management,
· cost estimations,
· scheduling,
· general techniques.
and specialists of GEC Alsthom for the electric power plant.
As for general techniques, there will be different specialists in:
· civil works and structurals,
· vessels,
· buildings,
· fluids,
· mechanical,
· lifting, handling and transport,
· electrical, instrumentation and automation.
The main purpose of involving specialists of general techniques will be to find, on the basis of AP's process data and considering site conditions, the best technical and cost solutions for building the project. In particular:
· Civil works
SOFRESID will investigate the type of foundations which are the most appropriate to the characteristics of the soil, as a function of the type of building and forces applied.
In the absence of precise data on the site selected, SOFRESID can achieve a good approach of the problem by using information on a nearby site (QAPCO). Indeed, this site is well known to SOFRESID because it participated to studies for extensions.
Moreover, SOFRESID is well aware of the particular problems of design of concrete structures related to local conditions (temperatures, maritime environment, etc...), and of the possibilities of local supplies in the region (capacity, characteristics, rebars, with or without linings, etc...).
· Metallic structures and vessels
During the pre?feasibility stage, SOFRESID will consider the design of structures taking into account:
¨ the regulatory constraints,
¨ process constraints,
¨ consistency with the various other disciplines (e.g. civil, roofing, cladding, lighting, etc...) and the choice of materials,
¨ local climatic conditions (insulation, protection, ventilation, etc...),
¨ consistency with the construction modes and the problems of supply and erection.
This work is conducted in close co-operation with the specialists of civil works, in order to achieve optimal technical and economic definition of the set foundations?structures.
· Mechanical, lifting, handling, transport
SOFRESID will take climatic conditions into account, for the design of all installations in order to avoid the problems related with the presence of sand and with maritime environment.
Particular attention will be given to the protection of mechanisms, to the selection of transport modes and to the definition of storage areas particularly in view of the relative long distance of the port to the site.
· Electrical and automation
SOFRESID will take climatic conditions into consideration, for selecting the technology of equipment, in order to avoid problems related with:
¨ high ambient temperature,
¨ maritime environment,
¨ presence of sand.
which are important points likely to affect the good operation of switching equipment (switch?gear, circuit?breakers) and electronic components.
SOFRESID will take advantage of experience gathered in the construction of previous projects in the fields of oil and gas.
In particular, SOFRESID will co-ordinate and manage the inter?faces between the different sub?assemblies related with the production and the distribution of energy, automation, transmissions and telecommunications.
Finally and more generally:
· SOFRESID will optimise the integration of both the Power Plant and Smelter on the site.
· SOFRESID will optimise the definition of all civil works, buildings, utilities, and maintenance shops, taking into account already at pre-feasibility stage the data provided by AP and QGPC and the possibility of obtaining local labour and/or local sub?contractors.
3.1.2. SERVICES TO BE PROVIDED
Within the framework of the pre-feasibility study, SOFRESID services will be as follows:
3.1.2.1. GENERAL
· Mobilisation of a team of specialists in the various disciplines involved:
· Preparation of a project kick-off meeting to be held in DOHA (issuance of a questionnaire),
· Collection of basic data from QGPC and AP,
· Analysis of the basic data supplied and of the information received at site.
3.1.2.2. DIRECT CAPITAL COST ESTIMATE
· Review of local contractors likely to undertake part of the fabrication and construction work, visits to their workshops and assessment of their capabilities.
· Preparation of, and invitation to submit, prequalification bids by selected local contractors.
· Definition of the roads and miscellaneous networks, utilities, general services depending on requirements, existing situation and background.
· Definition of the harbour facilities (unloading, storage, traffic, loading) required for the project and the possible extensions envisaged.
· Expert evaluation and undertaking of topographical surveys of the site considered by QGPC for the construction of both the smelter and electric power station.
· Definition of the type of foundations to be adopted, depending on soil quality data provided by QGPC.
· Sizing of the different process, support and office buildings, depending on AP's technical data and local climatic conditions.
· Assessment of quantities involved (tonnage and volumes), in the various disciplines.
· Requests for preliminary bidding documents by manufacturers for the supply of major equipment packages and/or specific smelter plant and equipment e.g.:
¨ main substation,
¨ alumina unloader,
¨ specific handling equipment,
¨ pot shells,
¨ super structures,
¨ pot gas treatment centres,
¨ refractories for the potline and the anode baking furnace,
¨ PTA, Furnace Tending Assemblies (FTA), Cathode Transport Crane (CTC) servicing machines,
¨ cathode block sealing machine,
¨ lining machines,
¨ standard overhead cranes,
¨ anode paste tower,
¨ casthouse cleaning, skimming and stirring machine,
¨ holding furnaces,
¨ ingot manufacturing lines,
¨ anode storage and reclaiming cranes,
¨ anode rodding line,
¨ anode and ladle transport vehicles, etc...
N.B. List of suppliers consulted will be prepared in agreement with QGPC and AP, in particular for all equipment items specific to the process.
· Assessment of the cost of the other items of equipment on the basis of recent project implementations, the data gathered from local contractors and SOFRESID's database.
· Assessment of the cost of the electric power station on the basis of the information supplied by GEC ALSTHOM.
· Detailed cost data provided by GEC?Alsthom, will be analysed by SOFRESID, in particular those data which concern concrete works, metallic structures and utilities, in order to homogenise them with those adopted for the cost estimations of the smelter.
· Determination of local and foreign cost components.
3.1.2.3. TECHNICAL DESCRIPTION
On the basis of the technical information supplied by AP and of the preliminary studies undertaken by SOFRESID and GEC?Alsthom, as described here?above, SOFRESID will establish a technical description; this will mainly cover the following:
· a general technical description of both the smelter and the power station.
· a memorandum justifying the configuration adopted for the power station.
· a memorandum describing the power station operation.
3.1.2.4. EPCM AND TEMPARY FACILITIES ESTIMATE
Assessment of the costs of the other services related with the project implementation:
· EPCM costs
¨ Direction of the project,
¨ Social relations,
¨ Accounts, cash,
¨ project control, scheduling, cost,
¨ engineering,
¨ procurement,
¨ contruction management,
¨ quality assurance,
¨ pre?operating testing.
· Miscellaneous costs and temporary installations
¨ local offices,
¨ temporary installations on site,
¨ ware housing,
¨ travel and catering of personnel moved from headquarters to site,
¨ local transport costs,
¨ telecommunications,
¨ document reproduction,
¨ computer, data processing and CAD.
3.1.2.5. START UP COST
Start-up costs will be estimated in agreement with AP and QGPC.
3.1.2.6. WORKING CAPITAL
Working capital will be estimated in agreement with AP and QGPC.
3.1.2.7. IMPLEMENTATION SCHEDULE
SOFRESID will draw up the preliminary schedule for the project implementation (engineering, procurement, construction, testing) accounting for :
· its own experience,
· the technical characteristics of the present project,
· the impact of equipment (transport and customs clearance duration)
· the local labour resources (working time, shift work schedules) and their related costs.
3.1.2.8. CAPITAL EXPENDITURE SCHEDULE
SOFRESID will draw up the capital expenditure schedule for each currency.
3.1.2.9. OPERATION COST
Assessment of the various costs related with the operation of the power plant and the smelter plant, including :
· management costs,
· labour costs,
· raw materials,
· power supply,
· spare parts,
· consumables.
3.1.2.10. REPORTS
· SOFRESID will draw up the pre-feasibility study dossier, on the basis of the above-mentioned data (10 copies).
· SOFRESID will draw up an Executive Report.