aspasa eastern cape regional committee meeting_20151008-without scc video
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Concrete for Wind Turbine Towers
ASPASA-SARMA Regional Committee Meeting October 2015
Santie Gouws
Concrete Tower Manager
santie.gouws@acciona.com
AGENDA
Acciona Windpower Overview
South African Wind Energy Industry
Acciona Windpower’s Concrete Towers
- Industrialized precast manufacture
- Overview of tower construction and manufacture of concrete segments
Why Concrete Towers?
- High strength SCC to EN 206
1
South African Wind Energy Industry
Integrated Resource Plan 2010-2030
South Africa
SOUTH AFRICAN WIND ENERGY INDUSTRY
SANTIE GOUWS
DoE presented IRP 2010 to 2030 in 2010 to diversify South African electricity generation mix:
Source Initial capacity 2010 Addition 2010-2030 Final Capacity 2030
Coal 24.6 GW - 74.8% 16.4 GW 41.1 GW - 46%
Natural Gas 2.4 GW - 7.2% 4.9 GW 7.3 GW - 8.2%
Nuclear 1.8 GW - 5.4% 9.6 GW 11.4 GW - 12.7%
Hydro 2.1 GW - 6.3% 3.3 GW 5.4 GW - 6.0%
Wind 0 GW - 0% 9.2 GW 9.2 GW - 10.3%
Solar PV 0 GW - 0% 8.4 GW 8.4 GW - 9.4%
Solar CSP 0 GW - 0% 1.2 GW 1.2 GW - 1.3%
TOTAL 33 GW 56.5 GW 89.5 GW
RE Independent Power Producer Procurement Programme
South Africa
SOUTH AFRICAN WIND ENERGY INDUSTRY
SANTIE GOUWS
DoE’s REIPPP Programme engages private companies to generate renewable energy through several bid windows:
WIND Awarded Nr of Projects Capacity COD
Round 1 Dec 2011 7 626 MW (wind only) 2nd half 2013
Round 2 May 2012 7 571 MW (wind only) 1st half 2015
Round 3 Oct 2013 7 787 MW (wind only) 1st half 2016
Round 4a April 2015 5 676 MW (wind only)
Round 4b June 2015 7 687 MW (wind only)
Expedited bid 1st Qtr 2016 ? 1800 MW (all renewables)
Round 5 onwards 2016 - 2018 ? 6300 MW (all renewables)
SOUTH AFRICAN WIND ENERGY INDUSTRY
SANTIE GOUWS
Distribution of Bid 1 to 4 Projects
Importance of Local Economic Development in REIPPP Programme
South Africa
SOUTH AFRICAN WIND ENERGY INDUSTRY
SANTIE GOUWS
Project Qualification is based on:
Environment, Land, Commercial
Economic Development Finance Technical
Project Evaluation is based on:
Price________________________________70%
Economic Development_________________30% - threshold up to round 4 ~ 40%
- set to increase from round 5 onwards
Local Spend
Job Creation
ED Scorecard
Cost of Electricity
2
Why Concrete Towers?
South Africa
WHY CONCRETE TOWERS? SANTIE GOUWS
Wind turbine development – turbine size and hub height
South Africa
WHY CONCRETE TOWERS? SANTIE GOUWS
Wind energy project value
Source: DTI based on Bid
Window 3 data for South
Africa
Concrete Towers > 95% local content
Concrete Towers are cost effective > 90m
Local Economic Development
Price
Further advantages of concrete towers
South Africa
WHY CONCRETE TOWERS ?
SANTIE GOUWS
Tower diameter and segment size not limited based on transport limitations
Further advantages of concrete towers
SANTIE GOUWS
Possibility to manufacture in remote locations, reduce transport cost and impact on roads and employ local labour from wind farm locale
WHY CONCRETE TOWERS?
3
ACCIONA Windpower Overview
OVERVIEW OF ACCIONA WINDPOWER
SANTIE GOUWS
Countries with AWP turbines installed
Widespread international footprint to capture future growth in the most attractive markets
A high quality wind turbine manufacturer with a global presence
Strong proprietary technology portfolio:
Fully in-house developed and certified turbine design
In-house blade design
Patented and certified concrete tower design
OVERVIEW OF ACCIONA WINDPOWER
Acciona Windpower presence
Designs and produces reliable and one of the lowest cost of energy wind turbines for Class I, II and III winds:
1.5 MW
3.0 MW
6.0 MW under development
SANTIE GOUWS
SANTIE GOUWS
Manufacturing
Vertical integration strategically limited to the key components (i.e. blades, towers and software control)
SUPPLIERS
Blades Towers Software control Yaw Gearboxes Generator
Local Manufacturers
OWN SUPPLY (Concrete towers)
REASON
LM controls the market.
Superior in-house design
Local markets with low value added
from technologies, except for concrete
Critical to optimize performance of turbines
Mature market Mature market Mature market
OVERVIEW OF ACCIONA WINDPOWER
Dimensions of AWP 3.0 MW Wind Turbine Generators
OVERVIEW OF ACCIONA WINDPOWER
Blades:
Length: 48m – 61.5m
Weight: 10t – 12t
SANTIE GOUWS
Nacelle & Hub:
Length: 17.6m
Weight: 140t
Tower:
Length: 87.5 to 95.5m (Steel); 100 to 120m (Concrete)
Weight: 290t (95.5m Steel); 1180t (120m Concrete)
South Africa
OVERVIEW OF ACCIONA WINDPOWER
SANTIE GOUWS
4
ACCIONA Windpower Concrete Towers
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Overview of Concrete Tower Construction Process
Segment Manufacture
• Industrialized Precast
• High Strength SCC
• 20m long segments
• 60tonnes/segment
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Overview of Concrete Tower Construction Process
Transport
Pre-Assembly
• 20m cylinders
• Vertical Joints
• Small cranes only
• 2 t/w
• 1-2 weeks ahead of erection
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Overview of Concrete Tower Construction Process
Pre-Assembly Phase
• 17/22 segments/tower for 100/120m tower
• Level 0 – 5 segments (120m tower)
• Level 1 – 4 segments (100m tower)
• Level 2 – 4 segments
• Level 3 – 4 segments
• Level 4 – 3 segments
• Level 5 – 2 segments
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Overview of Concrete Tower Construction Process
Final Assembly Phase
• Crawler crane 1-d operation
• 2t/w or more
• Independent of horizontal joint execution
• Independent external post-tensioning of tower
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Overview of Concrete Tower Construction Process
Final Assembly Phase
• Same crane as needed for nacelle
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Overview of Concrete Tower Construction Process
DESIGNED FOR (global) RE-PRODUCTION
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Overview of Concrete Segment Manufacturing Process
Casting Schedule
• 1 mould/tower level
• 5/6 for 100/120m t
• 1 to 2 casts/mould/d
• 6d/w
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Overview of Concrete Segment Manufacturing Process
Batching/casting
• Wet-batch only
• Ready-mix and/or pump
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Overview of Concrete Segment Manufacturing Process
Concrete Specification
• Self compacting concrete
• Flow of 750 mm
• Superplasticizers to reduce w/b ratio to < 0.35
• Highly sensitive to moisture, gradings and temperature
• Requires stringent control of raw materials and batching process
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Overview of Concrete Segment Manufacturing Process
Concrete Specification
• EN 206/EN 1992
• fcu = 75 MPa cube
• Demould at 25 MPa
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Overview of Concrete Segment Manufacturing Process
Finishing and Repair
• Segments functional requirements for tower construction and operation
• Vertical Joints
• Starter bars and Horizontal joints
• Internal tower fixtures
• Surface finish
• Managed through quality system
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Overview of Concrete Segment Manufacturing Process Quality Management
• Linked to tower certification
• Stringent measurement and recording of all aspects
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Overview of Concrete Segment Manufacturing Process Quality Management
• Paper-trail controlling all aspects and ensuring traceability
• From raw materials receipt to batch records to placing of steel and concrete, test results and numbering of segments through to position in tower
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Industrialized precast construction Industrialized precast
• Fast-track construction
• Linked to wind farm construction schedule
• Planning and logistics management of all processes
• Planning of factory lay-out and schedule
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Industrialized precast construction Industrialized precast
• Fast-track construction
• Linked to wind farm construction schedule
• Planning and logistics management of all processes
• Planning of factory lay-out and schedule
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Industrialized precast construction Industrialized precast
• Fast-track construction
• Linked to wind farm construction schedule
• Planning and logistics management of all processes
• Planning of factory lay-out and schedule
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Industrialized precast construction Industrialized precast
• Fast-track construction
• Linked to wind farm construction schedule
• Planning and logistics management of all processes
• Planning of factory lay-out and schedule
ACCIONA WINDPOWER CONCRETE TOWERS
SANTIE GOUWS
Industrialized precast construction
Thank you
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