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Development and Expansion Project, Diageo

Location: Addis Ababa, Ethiopia
Client: Diageo
Project: Project Walia
Contract Value: £8.89m

Boulting’s International Business Unit successfully won a competitive tender to provide a complete turn key solution for a brewery development and expansion on a newly acquired facility just outside of Addis Ababa, Ethiopia. The total engineering solution combined the expertise of Boulting’s electrical and mechanical engineers and their working knowledge of worldwide shipping.

Skilled and experienced management to implement high UK and EU standards

Whilst being cost-competitive, there was equal pressure on meeting a demanding programme of design, procurement, installation and commissioning. Equipment for the project was purchased and shipped from America, Turkey, Egypt and UK. Mobilisation, site establishment and receipt of shipments on site commenced three months after placement of order, with works being carried out utilising a core ex-pat management and supervision team.

Legacy of knowledge transfer to local workforce

As part of Boulting’s Corporate Social Responsibility we employed local labour, and working closely with them have passed on knowledge of our installation practises, Health & Safety culture and training in the operation and maintenance of the equipment. Conditions in country were demanding with an altitude of 2356m and gradients of 1:5.

Civil Works

Civil works encompassed foundations for Pipebridge and support structures and direct buried cabling, road crossings and cable draw pits.

Electrical Works included automated control system for efficiency

Electrically, a 3000kVA Generator was purchased from USA, containerised in the UK and shipped to Ethiopia. A 15kV High Voltage primary switchboard, 15kV High Voltage ring main units and 11 off ONAN transformers have been shipped and installed. A generator and synchronisation control system were designed and installed so that the existing 2275kVA generator and the new 3000kVA generator can either run individually or be synchronised together and automatically governed to support the fluctuating demand. 4,400m high voltage and 14,100m of low voltage cabling were installed on 1,500m of racking, LED lighting in bottling hall 3 has also been installed. Earthing systems; earth nests, earthing and bonding were incorporated also.

Extensive mechanical works designed, fabricated and installed

Scope included replacement of existing boiler with a 15 tonne/hour steam boiler weighing 36 tonne and installation of a new 20,000 litre insulated stainless steel hot well with associated carbon steel blowdown vessel. A new 2,300m3/hr compressed air dryer, filters, aftercooler, and a 1,300 litre Air Receiver were also installed. Design, fabrication and installation of new Pipebridges with walk ways and 5,500m of bottling line services pipework comprising of: Steam and Condensate in Carbon Steel and Beer Lines, DAL, CO2, CIP, Glycol, Compressed Air and Caustic in Stainless Steel, plus 3 new water systems (process, service and product).

Consistently high Health and Safety standards

Health and safety was a collaboration with the client and sub contractors with notice boards being in English and Amharic. Boulting worked 110,000 hours to date with zero lost time accidents which was a contributing factor to the client celebrating 800,000 hours on the project with zero lost time accidents.

Shipping challenges overcome by international project experience

Shipping of equipment created some additional challenges. With Ethiopia being land locked all goods had to be shipped via sea to Djibouti and then transported by road to site in Ethiopia including the 36 Tonne boiler and 45 Tonne Containerised Generator. Thirty-two 40ft containers and twelve 20ft containers were sent via sea-freight along with eight smaller air-freight shipments and hand carried items when returning to site.

Reduced carbon foot print and substantial cost savings for client

A number of conscious decisions were made to both reduce and recover energy, lowering costs and Carbon Footprint. For the first time in Africa we installed energy efficient LED lighting in the bottling hall which will reduce energy consumption and increase lamp life by 4 times in comparison to metal halide. A Donaldson after cooler and heat exchanger was installed to recover heat from the compressed air lines which in turn feeds into the hot well. The condensate is also recovered and returned to the hot well, this is then fed into the boiler as pre heated water.

Factory acceptance tests were carried out on capital equipment prior to shipping. Installation was carried out on site, inspected and tested before subsequent performance tests and formal hand-over to client.

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