Onshore Windfarm Part 2

27
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

description

The second presentation of our second lecture on Onshore Windfarms.

Transcript of Onshore Windfarm Part 2

Page 1: Onshore Windfarm Part 2

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

Page 2: Onshore Windfarm Part 2

Renewables Conference

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

Page 3: Onshore Windfarm Part 2

Renewables Conference

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

Page 4: Onshore Windfarm Part 2

Renewables Conference

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

Page 5: Onshore Windfarm Part 2

Renewables Conference

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

Page 6: Onshore Windfarm Part 2

Renewables Conference

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

Page 7: Onshore Windfarm Part 2

Renewables Conference

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

Page 8: Onshore Windfarm Part 2

Renewables Conference

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

Page 9: Onshore Windfarm Part 2

Renewables Conference

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

Page 10: Onshore Windfarm Part 2

Renewables Conference

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

Page 11: Onshore Windfarm Part 2

Renewables Conference

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

Page 12: Onshore Windfarm Part 2

Renewables Conference

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

Page 13: Onshore Windfarm Part 2

Renewables Conference

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

Page 14: Onshore Windfarm Part 2

Renewables Conference

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

Page 15: Onshore Windfarm Part 2

Renewables Conference

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

Page 16: Onshore Windfarm Part 2

Renewables Conference

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

Page 17: Onshore Windfarm Part 2

Renewables Conference

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

Page 18: Onshore Windfarm Part 2

Renewables Conference

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

Page 19: Onshore Windfarm Part 2

Renewables Conference

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

Page 20: Onshore Windfarm Part 2

Renewables Conference

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

Page 21: Onshore Windfarm Part 2

Renewables Conference

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

Page 22: Onshore Windfarm Part 2

Renewables Conference

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

Page 23: Onshore Windfarm Part 2

Renewables Conference

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

Page 24: Onshore Windfarm Part 2

Renewables Conference

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

Page 25: Onshore Windfarm Part 2

Renewables Conference

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

Page 26: Onshore Windfarm Part 2

Renewables Conference

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

Page 27: Onshore Windfarm Part 2

Renewables Conference

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