onshore windfarm part 2
DESCRIPTION
The second presentation of our second lecture on Onshore Windfarms.TRANSCRIPT
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Renewables Conference
Onshore Windfarms
Construction and Operation
ICE Scotland
Edinburgh and Area Branch G&S
21 March 2012
Jim Wilkinson BEng CEng MICE
Contracts Manager
Onshore Windfarm
Construction and Operation
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Introduction
� C A Blackwell are a privately owned civil engineering contractoroperating nationally
� Established in 1956
� Directly employ around 110 staff and over 400 skilled operatives
� One of the largest privately owned
plant fleets in the UK with over
300 items of major plant
� Offices in Earls Colne, Tewkesbury,
Wakefield and Grangemouth
Onshore Windfarm
Construction and Operation
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Onshore Windfarm experience
� Staff have, in the aggregate, experience of over 30 windfarm projects
� Extensive experience of Scottish onshore sites� Projects currently in hand include
� Clyde South 56 Turbines (SSER)� Clyde North 27 Turbines (SSER)� Carraig Gheal 20 Turbines (GreenPower)� Clashindarroch 18 Turbines (Vattenfall)� Withernwick 9 Turbines (EnergieKontor)� Crookhill 12 Turbines (Coronation Power)
Onshore Windfarm
Construction and Operation
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Onshore Windfarm
Construction and Operation
Construction scope
� Typical Scottish Windfarm project size� £20M+ BOP / D&B
� 20+ 3.5MW WTG
� 30 – 60km access tracks
� Off site enabling works
� Location� Geographically remote
� Poorly connected to infrastructure
� Exposed weather conditions
� Sensitive ecological constraints
� Poor ground conditions
� Programme � Time critical
� 12+ month programme
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Onshore Windfarm
Construction and Operation
Pre-Construction : Organisation
� Organisational structure
� Contractor multi disciplined team� 50 professional and management positions
� 250 operatives
� 150 contractors and subcontractors
� Client multi disciplined team
� 20 professional and management positions� Project management team
� ECOW
� CDM-C / H&S Advisor
� Technical Authority / Engineer
� Bank Engineers
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Project Director
Contracts Manager Commercial Manager
Environmental Manager
Quality Manager
Agent
Windfarm
&Sub Station
Structures
& Batching
Project Manager
H&S Advisor
Project QS
QS
Visiting
Site based
Professional Services
H&S Manager
HSEQ Manager
Tracks
&Quarry Operations
Work Activity
Design Coordinator
Section Engineers
Design coordination
&Surveying
Assistant QS
Electrical
General Foremen
Setting Out Engineers
Environmental Advisor
EnvironmentalSquads
Electrical teams
Labour / Plant / Equipment / Sub-contractors
Electrical ManagerAgentAgent
General Foremen General Foremen
Sub Agents
Section Engineers Section Engineers
Sub Agents Sub Agents
Section Foremen Section Foremen Section Foremen
Civil Design
Land Surveyors
Electrical Design
Commercial
&Contractual
Cabling teams
Plant Manager
Plant Yard
&Vehicles
Plant Fitters
Plant Maintenance
Onshore Windfarm
Construction and Operation
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Pre-Construction : Site establishment
� Site establishment� Main project office accommodation for circa 100 persons
� Provision of power, water, sewerage and cleaning services
� Installation of IT and communications
� Access control and site security
� Construction of parking areas for around 100 vehicles
� Construction of plant yard and maintenance facilities
� Construction of materials storage and lay-down areas
� Installation of batching plant
� Installation of satellite offices
Onshore Windfarm
Construction and Operation
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Pre-Construction : Communications
� Communications Plan
� Office communications� External offices
� Internet connectivity
� Data transfer
� Mobile phone coverage
� Site wide communications� Site satellite offices
� Mobile phone coverage
� Radio communications
� Emergency channel
Onshore Windfarm
Construction and Operation
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Pre-Construction : Access
� Construction access arrangements
� Public roads� Liaison with Police and Roads Authority
� Existing road network and restrictions
� Road improvements for delivery vehicles
� Site access � Site access control
� Third party arrangements, FCS, land owners, etc
� Underground and overhead service protection
� Temporary site access tracks
� Traffic Management Plan� Warning and advisory signage
� Emergency Plan
Onshore Windfarm
Construction and Operation
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Pre-Construction : Security of supply
� Security of supply in busy market conditions
� Staff� Experienced motivated key staff
� Plant� Large internal plant fleet
� Internal batching plant and equipment
� Labour� Large internal skilled workforce
� Preferred supplier contracts
� Provision of worker camps / accommodation facilities
� Sub-contractors� Preferred suppliers and approved vendors
Onshore Windfarm
Construction and Operation
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Construction Planning � Programme
� Lead in period ideally 12 weeks
� Key milestone dates
� Grid transformer delivery
� Grid connection
� Turbine delivery
� Power generation
� Constraints� Planning
� Lease agreements
� Ecological
� Risks� Weather
� Ground conditions
Onshore Windfarm
Construction and Operation
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Health and Safety Planning
� Competence:� Identification and assessment of skills;
� Information, Instruction and Training;
� Control:� Standards and expectations outlined from the start;
� Safety lead from the top down;
� H & S responsibilities clear and all parties held accountable.
� Co-operation:� Daily co-ordination involving all parties;
� Contractor work review;
� Establishment of safety committee.
� Communication:� Construction Phase Plan;
� Used as site management tool - NOT generic;
� Site specific induction;
� Tool box talks, daily task briefings etc.
Onshore Windfarm
Construction and Operation
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Environmental Planning � Environmental Management Plan
� Environmental Method Statement
� Pollution Prevention Plan
� Water Quality Monitoring Plan
� Pollution Incident Plan
� ECOW co-ordination� ECOW daily log
� Constraints management and monitoring
� Third party liaison� SEPA, SNH, Planning Authority, FCS and others
� Environmental Management� Full time Environmental Manager and Advisors
� Continuous improvement Plan
Onshore Windfarm
Construction and Operation
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Construction Operations
� Enabling works for turbine and grid transformer delivery
� Design swept path analysis� Road improvements
� Site access junction
� Exceptional loads and clearances� Service diversions
� Tree surgery
� Traffic Management Plan� Liaison with Police and Roads Authorities
� Temporary traffic management
Onshore Windfarm
Construction and Operation
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Construction Operations : Track alignment
Topographic survey and peat probes
Consider ecological constraints
Draft alignment design
Submit micro-siting for approval
Final alignment design
Forestry clearance
Consider watercourse crossings
Set out consented alignment
Consider ground conditions
Earthworks balance
Construction issue drawings
Onshore Windfarm
Construction and Operation
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Construction Operations : Track details
� Floating track
� Criteria� Peat depths generally >1.0m
� CBR >0.5%
� Undisturbed surface
� Construction detail� Geogrid or brash mat
� Processed rock 125mm down
� Generally 800mm depth of construction
Onshore Windfarm
Construction and Operation
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Construction Operations : Track details
� Plant and equipment� 3 man geogrid handling squad
� Dozer
� 14T roller
� 20T excavator
� 3 no 30T ADT
� Production� Typically 125-200m per day
� Dependant on stone supply
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Construction Operations : Track details
� Cut to fill track
� Criteria� Peat depths generally <1.0m
� CBR >5%
� Construction detail� As raised rock 250mm down
� Earthworks balance
� Optimised volume and mass haul
Onshore Windfarm
Construction and Operation
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Construction Operations : Track details
� Plant and equipment� 2 no 14T LGP excavators
� 45T excavator and breaker
� 30T excavator and breaker
� D65 Dozer
� 14T roller
� 3 no 30T ADT
� Production� Typically 50-125m per day
� Dependant on topography, depth of overburden, in-situ rock strength, mass haul and stone supply
Onshore Windfarm
Construction and Operation
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Construction Operations : Borrow pits
� Consented borrow pits
� QR99 compliance� Quarry plan
� Signage, drainage and fencing
� Forestry clearance / Overburden strip
� Drilling and blasting operations
� Rock processing� Concrete aggregates
� Floating roads
� Structural backfill
� Track surfacing
� Restoration
Onshore Windfarm
Construction and Operation
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Construction Operations : Permanent drainage
� Permanent drainage design
� Drainage philosophy
� Track drainage� SUDS approach
� Watercourse crossings� CAR registration and licensing
� Bridges generally >2m in bed
� Piped crossings generally <2m in bed
� Ecological constraints
� Water supply points
Onshore Windfarm
Construction and Operation
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Construction Operations : Temporary drainage � Temporary drainage design
� Guidance documents� Environmental Statement
� Constraints
� SEPA, SNH, CIRIA and FCS publications
� Forests and Water Guidelines published by FCS
� The Good Practice During Windfarm Construction guidance documentpublished jointly by Scottish Renewables, SEPA, SNH and FCS
� SEPA Good Practice Guides and PPG 1, PPG5 and PPG6
� SNH Floating Roads On Peat
� Control measures� Temporary drainage plans
� Silt mitigation plans
� Water quality monitoring
Onshore Windfarm
Construction and Operation
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Construction Operations : Concrete production
� Site batching plant and equipment� Batching plant
� Mixer trucks
� Establishment� Layout
� Water supply
� Material deliveries
� Quality control� Mix design
� Testing
� Quality control
Onshore Windfarm
Construction and Operation
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Construction Operations : WTG bases
� Design type� Assume 3.5MW with 78m hub height
� Submerged gravity base
� Cast in bolt set
� Construction activities� Earthworks and testing
� Blinding concrete
� Rebar circa 56T
� Ducts, earthing and bolts
� Base pour 300m3 40N concrete
� Plinth pour 50m3 50N concrete
� Backfill and earthing mat
Onshore Windfarm
Construction and Operation
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Construction Operations : Electrical works
� Electrical design� P28 studies
� Grid code compliance
� Resistivity testing
� Cable layout
� Electrical long lead items� Transformers
� Cables
� Sub-station building
� Grid transformer delivery
� Cabling
� SCADA /communications system
� Energisation
Onshore Windfarm
Construction and Operation
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Construction Operations : WTG installation
� Turbine delivery� Traffic coordination
� Lay down areas and storage
� Road condition monitoring and maintenance
� Turbine erection� Lifting Plan
� Erection programme
� Turbine bolt grouting
� Electrical interface� Energisation
� Commissioning
Onshore Windfarm
Construction and Operation
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Construction Operations : PC Role
� PC Role duties � Overarching health and safety responsibility
� Daily contractor coordination
� Contractor RAMS approval
� Access and security
� Establishment and welfare
� Track and hardstanding maintenance
Onshore Windfarm
Construction and Operation