Onshore Windfarm Part 2

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The second presentation of our second lecture on Onshore Windfarms.

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Onshore Windfarm Part 2

  1. 1. Onshore Windfarm Construction and Operation Onshore Windfarms Construction and Operation ICE Scotland Renewables ConferenceEdinburgh and Area Branch G&S 21 March 2012 Jim Wilkinson BEng CEng MICE Contracts Manager
  2. 2. Onshore Windfarm Construction and Operation IntroductionC A Blackwell are a privately owned civil engineering contractoroperating nationallyEstablished in 1956 Renewables ConferenceDirectly employ around 110 staff and over 400 skilled operativesOne of the largest privately ownedplant fleets in the UK with over300 items of major plantOffices in Earls Colne, Tewkesbury,Wakefield and Grangemouth
  3. 3. Onshore Windfarm Construction and Operation Onshore Windfarm experienceStaff have, in the aggregate, experience of over 30 windfarmprojectsExtensive experience of Scottish onshore sitesProjects currently in hand include Renewables Conference 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)
  4. 4. Onshore Windfarm Construction and Operation Construction scopeTypical Scottish Windfarm project size £20M+ BOP / D&B 20+ 3.5MW WTG 30 – 60km access tracks Renewables Conference Off site enabling works Location Geographically remote Poorly connected to infrastructure Exposed weather conditions Sensitive ecological constraints Poor ground conditionsProgramme Time critical 12+ month programme
  5. 5. Onshore Windfarm Construction and Operation Pre-Construction : OrganisationOrganisational structureContractor multi disciplined team 50 professional and management positions Renewables Conference 250 operatives 150 contractors and subcontractorsClient multi disciplined team20 professional and management positions Project management team ECOW CDM-C / H&S Advisor Technical Authority / Engineer Bank Engineers
  6. 6. Onshore Windfarm Construction and Operation Project Director HSEQ Manager Contracts Manager Commercial Manager H&S Advisor H&S Manager Quality Manager Environmental Environmental Civil Design Electrical Design Advisor Manager Project Manager Agent Agent Agent Renewables Conference Design Coordinator Electrical Manager Project QS Plant Manager Tracks Structures Windfarm Design coordination Electrical Commercial Plant Yard & & & & & &Quarry Operations Batching Sub Station Surveying Contractual Vehicles Sub Agents Sub Agents Sub Agents Setting Out Engineers Electrical teams QS Plant FittersGeneral Foremen General Foremen General Foremen Land Surveyors Cabling teams Assistant QS Plant MaintenanceSection Engineers Section Engineers Section EngineersSection Foremen Section Foremen Section Foremen Environmental Squads Professional Services Labour / Plant / Equipment / Sub-contractors Site based Work Activity Visiting
  7. 7. Onshore Windfarm Construction and Operation Pre-Construction : Site establishmentSite establishment Main project office accommodation for circa 100 persons Provision of power, water, sewerage and cleaning services Renewables Conference 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
  8. 8. Onshore Windfarm Construction and OperationPre-Construction : Communications Communications Plan Office communications Renewables Conference External offices Internet connectivity Data transfer Mobile phone coverage Site wide communications Site satellite offices Mobile phone coverage Radio communications Emergency channel
  9. 9. Onshore Windfarm Construction and Operation Pre-Construction : AccessConstruction access arrangements Public roads Liaison with Police and Roads Authority Renewables Conference Existing road network and restrictions Road improvements for delivery vehiclesSite 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
  10. 10. Onshore Windfarm Construction and Operation Pre-Construction : Security of supplySecurity of supply in busy market conditionsStaff Experienced motivated key staff Renewables ConferencePlant Large internal plant fleet Internal batching plant and equipmentLabour Large internal skilled workforce Preferred supplier contracts Provision of worker camps / accommodation facilitiesSub-contractors Preferred suppliers and approved vendors
  11. 11. Onshore Windfarm Construction and Operation Construction PlanningProgramme Lead in period ideally 12 weeks Key milestone dates Grid transformer delivery Grid connection Turbine delivery Renewables Conference Power generationConstraints Planning Lease agreements EcologicalRisks Weather Ground conditions
  12. 12. Onshore Windfarm Construction and Operation Health and Safety PlanningCompetence:Identification and assessment of skills;Information, Instruction and Training; Control: Standards and expectations outlined from the start; Renewables Conference 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.
  13. 13. Onshore Windfarm Construction and Operation Environmental PlanningEnvironmental Management Plan Environmental Method Statement Pollution Prevention Plan Water Quality Monitoring Plan Pollution Incident Plan Renewables ConferenceECOW co-ordination ECOW daily log Constraints management and monitoringThird party liaison SEPA, SNH, Planning Authority, FCS and othersEnvironmental Management Full time Environmental Manager and Advisors Continuous improvement Plan
  14. 14. Onshore Windfarm Construction and Operation Construction OperationsEnabling works for turbine and grid transformer deliveryDesign swept path analysis Renewables Conference Road improvements Site access junctionExceptional loads and clearances Service diversions Tree surgeryTraffic Management Plan Liaison with Police and Roads Authorities Temporary traffic management
  15. 15. Onshore Windfarm Construction and OperationConstruction Operations : Track alignment Set out consented alignment Forestry clearanceTopographic survey and peat probes Consider ecological constraints Renewables Conference Consider watercourse crossings Consider ground conditions Draft alignment design Earthworks balance Submit micro-siting for approval Final alignment design Construction issue drawings
  16. 16. Onshore Windfarm Construction and Operation Construction Operations : Track detailsFloating trackCriteria Peat depths generally >1.0m Renewables Conference CBR >0.5% Undisturbed surfaceConstruction detail Geogrid or brash mat Processed rock 125mm down Generally 800mm depth of construction
  17. 17. Construction Operations : Track detailsPlant and equipment 3 man geogrid handling squad Dozer Renewables Conference 14T roller 20T excavator 3 no 30T ADTProduction Typically 125-200m per day Dependant on stone supply
  18. 18. Onshore Windfarm Construction and Operation Construction Operations : Track detailsCut to fill trackCriteria Renewables Conference Peat depths generally <1.0m CBR >5%Construction detail As raised rock 250mm down Earthworks balance Optimised volume and mass haul
  19. 19. Onshore Windfarm Construction and Operation Construction Operations : Track detailsPlant and equipment 2 no 14T LGP excavators 45T excavator and breaker 30T excavator and breaker Renewables Conference D65 Dozer 14T roller 3 no 30T ADTProduction Typically 50-125m per day Dependant on topography, depth of overburden, in-situ rock strength, mass haul and stone supply
  20. 20. Onshore Windfarm Construction and Operation Construction Operations : Borrow pitsConsented borrow pitsQR99 compliance Quarry plan Signage, drainage and fencing Renewables Conference Forestry clearance / Overburden strip Drilling and blasting operationsRock processing Concrete aggregates Floating roads Structural backfill Track surfacingRestoration
  21. 21. Onshore Windfarm Construction and Operation Construction Operations : Permanent drainagePermanent drainage designDrainage philosophyTrack drainage Renewables Conference SUDS approachWatercourse crossings CAR registration and licensing Bridges generally >2m in bed Piped crossings generally <2m in bed Ecological constraints Water supply points
  22. 22. Onshore Windfarm Construction and Operation Construction Operations : Temporary drainageTemporary drainage designGuidance documents Environmental Statement Constraints SEPA, SNH, CIRIA and FCS publications Forests and Water Guidelines published by Conference Renewables FCS The Good Practice During Windfarm Construction guidance document published jointly by Scottish Renewables, SEPA, SNH and FCS SEPA Good Practice Guides and PPG 1, PPG5 and PPG6 SNH Floating Roads On PeatControl measures Temporary drainage plans Silt mitigation plans Water quality monitoring
  23. 23. Onshore Windfarm Construction and Operation Construction Operations : Concrete productionSite batching plant and equipment Batching plant Mixer trucks Renewables ConferenceEstablishment Layout Water supply Material deliveriesQuality control Mix design Testing Quality control
  24. 24. Onshore Windfarm Construction and Operation Construction Operations : WTG basesDesign type Assume 3.5MW with 78m hub height Submerged gravity base Cast in bolt set Renewables ConferenceConstruction 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
  25. 25. Onshore Windfarm Construction and Operation Construction Operations : Electrical worksElectrical design P28 studies Grid code compliance Resistivity testing Renewables Conference Cable layoutElectrical long lead items Transformers CablesSub-station buildingGrid transformer deliveryCablingSCADA /communications systemEnergisation
  26. 26. Onshore Windfarm Construction and Operation Construction Operations : WTG installationTurbine delivery Traffic coordination Lay down areas and storage Renewables Conference Road condition monitoring and maintenanceTurbine erection Lifting Plan Erection programmeTurbine bolt groutingElectrical interface Energisation Commissioning
  27. 27. Onshore Windfarm Construction and Operation Construction Operations : PC RolePC Role duties Overarching health and safety responsibility Daily contractor coordination Renewables Conference Contractor RAMS approval Access and security Establishment and welfare Track and hardstanding maintenance

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