The Future is Modular

Untitled-2IDE’s modular approach to desalination solutions is heralding a new era of more competitive, efficient, ‎cost effective and eco-friendly plants for quick delivery, to be developed using the M2PD (Modular Market Preferred ‎Design) concept.  Deputy CEO Amnon Levy tells us more.‎

The journey to M2PD

The desalination history of IDE sets off in the 1960s using the method of ‎freezing (Zarchin Method) to desalinate sea water. The next step was the introduction of thermal systems using ‎evaporation and condensation. In the 1980s, IDE started using Reverse Osmosis (RO) technology and ‎even developed its own membranes. After a break of a few years, during which IDE focused on thermal desalination, and once RO technology matured, ‎the company resumed using RO.

In the 1990s, use of RO desalination became more established and IDE grew exponentially the size and quantity of the plants it was building. During those years, IDE broke world records. This started with the Eilat plant, built for the Mekorot Water Authority. This ‎plant included an RO train with output of 8,000 m3/day, which was the highest capacity train in the ‎world at that time. The next stage of development used similar trains to build a plant in Larnaca of 46,000m3/day.

The next step was the introduction of pressure centers, a revolutionary change in the planning concept, adding scalability to mega-size projects (projects with outputs of hundreds of thousands of cubic meters per day). The first desalination plant to use pressure centers was Ashkelon, which produced 330,000 m3/day per day.

When the Ashkelon plant went into operation, it was the largest of its kind in the world. The company then broke a further two world records in building the Hadera plant, and most recently, the plant in Soreq – the largest desalination plant of its kind in the world.

Organizational Change and a Rethink

‎“In 2009 an update of strategy compelled us to look at new ‎areas,” recalls Amnon. “We discovered a major desalination market that we had been overlooking during the previous decade – small and medium sized plants.” The advantage of these ‎markets was that the size of the projects meant that they were more frequent and enabled us to balance the fluctuation of the work loads with which our company has to cope within the large plants market. The challenge in this market, in which competitors were ‎already addressing this segment, was to differentiate IDE and to develop a competitive advantage.‎

The IDE PROGREENTM Technology

‎“We strove to provide a better and more financially viable solution than already existed in the market,” says Amnon. ‎‎“We looked at our RO process, which used five chemicals at IDE PROGREEN FRONTvarious stages, and ‎saw the potential for an eco-friendly, easy to operate RO process that didn’t require chemicals at all. This is how the eco-friendly desalination process of IDE PROGREENTM was born.”

The initial development and implementation of the process was at small, modular plants that were built as products, enabling quick delivery of the plant, which would be manufactured and inspected at the factory. It would be easy to transport and assemble, and would require minimal operational and maintenance work.

This is how the modularity of IDE PROGREENTM  was born.

Developing the Principle of M2PD

As part of the Wildly Important Goals (WIG) that were defined for 2014, the management of the company set a goal to improve IDE’s competitive advantage in mega-size SWRO projects through an 8% reduction in Engineering Procurement Construction (EPC) project costs, and a reduction of design, manufacturing and plant setup time by 20%. The decision was that this ambitious goal would be achieved through technological improvements; standardized design; use of standard equipment; modular planning and production; and improved procurement processes and costs of equipment purchased.

In order to achieve this challenging goal, the thought process and formulation of solutions began in the fourth quarter of last year, immediately following the definition of the WIG. Amnon explains, “After years of development and building of the most advanced desalination plants in the world, and answering dozens of tenders, we managed to combine the knowledge we’ve gained with customer requirements to create standard modules that will provide an optimal and modular solution to all sizes of RO plants, from the smallest with output of 500 m3/day up to mega-projects. The vision is the continuation and expansion of the WIG of 2013, which defined modular product development for outputs of 1,000-10,000 m3/day, and evolved into the full M2PD solution for all sizes of RO plants.”

The M2PD vision is about designing and manufacturing modular units that would form complete plants, with quick delivery time, and standard shipping with the modules packed in containers.

The M2PD principle will result in major savings in engineering and purchasing costs, high quality manufacturing and significant reduction of time for engineering, purchasing, manufacturing, set up and operations. It places emphasis on reducing setup efforts on site and reducing assembly time, which generally exposes us to exceeding the timeline and budget.

In order to transform the vision to reality, we will have to make deep changes to our work methods, as well as to how we think. We will have to look to the future and create an optimal balance between our customers’ requirements, conditions on site, and the M2PD solution, all the while taking a modular, product oriented approach.

Our long-term experience with planning and operating plants, combined with the M2PD concept, will give us a clear advantage in our competitive industry.

Projects Status

Vasilikos-SWRO

Location Vasilikos power plant-Cyprus
Project Scope Turn Key Supply of permanent SWRO desalination plant capable of producing 60,000 m^3/day of drinking water
Client EAC – Electricity Authority of Cyprus
Contractual Dates Effective Date : 28-February-2013

T.O.C Dated 1.8.2013
Project Manager Tsafrir Ben-Shlomo
Project Status Rood Developments & Punch list

00071 KohSichang Island-Modular RO

Location KohSichang, Thailand
Project Scope ProGreen Generic 20’ skided 1,000 m3/d SWRO
Client FLUID
Contractual Dates Effective Date : Contract signature September 29th 2013)

Delivery Date: FOB Israel End of Jan 2014, 16 weeks from contract signature
Project Manager Tal Oz-Ari
Project Status Design & Construction

00069 SanSha Island- Modular RO

Location Sansha Island, South China SEA
Project Scope ProGreen 500 m3/d SWRO plant Second Pass and Post treatment
Client BEWG - Beijing Enterprise Water Group
Contractual Dates Effective Date : October 29th 2013

Delivery Date: FOB Israel 4 month, End of Feb 2014
Project Manager Tal Oz-Ari
Project Status Construction

00044 Akshukur 1,000m3/d-Modular RO

Location Akshukur, Kazakhstan
Project Scope Supply (FOB) Supervise installation & commissioning of 1,000 m3/d BWRO
Client CROWN PLUS
Contractual Dates Effective Date : June 17th 2013

FOB Date: Feb 2014
Project Manager Tal Oz-Ari
Project Status Completed, Tested & Waiting for client to complete infrastructure on site

Hayman Island 1,000 m3/d-Modular RO

Location Hayman Island, Australia
Project Scope Delivery to site including permits, installation support and commissioning of 1,000 m3/d SWRO plant
Client MULPHA
Contractual Dates On site Date: Commissioning date Feb-March 2014
Project Manager Tal Oz-Ari
Project Status Testing & Packing before delivery to the Island

Reliance-MED

Location Jamnagar, India
Project Scope Supply 3 MED unit of 24,000 m^3/d, spare motors & mobile acid cleaning skid
Client Reliance Industries Limited, Mumbai India
Contractual Dates Effective date : 05-Apr-13

FOB dates :
Unit 1 – 05-May-14
Unit 2 – 05-Aug-14
Unit 3 – 05-Nov-14
Project Manager Dror Ayal
Project Status Manufacturing & purchasing

Andritz -MVC

Location Tocopilla, Chile
Project Scope FOB Supply 2 * 600 m3/day MVC + 2 years Spare parts
Client Andritz Energy & Environment GmBH
Contractual Dates Effective Date : 21-November-2012

FOB Date : 21-November-2013
Project Manager Ron Neulander
Project Status Shipped to client

Jamnagar-SWRO

Location Jamnagar, Gujarat state, India
Project Scope Design & equipment supply (FOB) for 7,000 m3/hr SWRO plant
Client Reliance Industries Ltd
Contractual Dates Effective Date : 24-June-2013

Equipment & design deliverables to be delivered up to 19 months from effective date
Project Manager Avi Amitai, Tsafrir Ben-Shlomo
Project Status Design & Equipment procurement in progress

Black Fox-MVC

Location Tocopilla, Chile
Project Scope FOB Supply 985 m3/day + 2 years Spare parts, Spare set of blades
Client E-CL
Contractual Dates Effective Date : 06-May-2013

FOB Date : 31-Aug-2014
Project Manager Ron Neulander
Project Status Manufacturing

PACO Panama -MVC

Location Punta Rincon, Province of Colon, Panama
Project Scope FOB Supply 2 * 960 m3/day MVC + Intake pumps and sand filters
Client SK E&C Korea
Contractual Dates Effective Date : 01-April-2013

FOB Date : 15-June-2014
Project Manager Ron Neulander
Project Status Manufacturing

Carlsbad-SWRO

Location California USA
Project Scope The scope of this project is to construct a 18,250 MG/year reverse osmosis (RO) seawater desalination facility
Client Kiewit Shea Desalination (KSD), Carlsbad California USA
Contractual Dates Effective Date : 28-Dec-2012

Contractual CPM Schedule is 35 month schedule

Aiming to stabilized 31 month schedule (currently 14-Aug-2015)
Project Manager Ziv Shor
Project Status 90% Design & under Construction