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Onshore Windfarm Part 2
- 1. Onshore Windfarm Construction and Operation Onshore Windfarms Construction and Operation ICE Scotland Renewables Conference Edinburgh and Area Branch G&S 21 March 2012 Jim Wilkinson BEng CEng MICE Contracts Manager
- 2. Onshore Windfarm Construction and Operation Introduction C A Blackwell are a privately owned civil engineering contractor operating nationally Established in 1956 Renewables Conference 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
- 3. Onshore Windfarm Construction and Operation 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 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. Onshore Windfarm Construction and Operation Construction scope Typical 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 conditions Programme Time critical 12+ month programme
- 5. Onshore Windfarm Construction and Operation Pre-Construction : Organisation Organisational structure Contractor multi disciplined team 50 professional and management positions Renewables Conference 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
- 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 Fitters General Foremen General Foremen General Foremen Land Surveyors Cabling teams Assistant QS Plant Maintenance Section Engineers Section Engineers Section Engineers Section Foremen Section Foremen Section Foremen Environmental Squads Professional Services Labour / Plant / Equipment / Sub-contractors Site based Work Activity Visiting
- 7. Onshore Windfarm Construction and Operation Pre-Construction : Site establishment Site 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. Onshore Windfarm Construction and Operation Pre-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. Onshore Windfarm Construction and Operation Pre-Construction : Access Construction access arrangements Public roads Liaison with Police and Roads Authority Renewables Conference 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
- 10. Onshore Windfarm Construction and Operation Pre-Construction : Security of supply Security of supply in busy market conditions Staff Experienced motivated key staff Renewables Conference 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
- 11. Onshore Windfarm Construction and Operation Construction Planning Programme Lead in period ideally 12 weeks Key milestone dates Grid transformer delivery Grid connection Turbine delivery Renewables Conference Power generation Constraints Planning Lease agreements Ecological Risks Weather Ground conditions
- 12. Onshore Windfarm Construction and Operation Health and Safety Planning Competence: 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. Onshore Windfarm Construction and Operation Environmental Planning Environmental Management Plan Environmental Method Statement Pollution Prevention Plan Water Quality Monitoring Plan Pollution Incident Plan Renewables Conference 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
- 14. Onshore Windfarm Construction and Operation Construction Operations Enabling works for turbine and grid transformer delivery Design swept path analysis Renewables Conference 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
- 15. Onshore Windfarm Construction and Operation Construction Operations : Track alignment Set out consented alignment Forestry clearance Topographic 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. Onshore Windfarm Construction and Operation Construction Operations : Track details Floating track Criteria Peat depths generally >1.0m Renewables Conference CBR >0.5% Undisturbed surface Construction detail Geogrid or brash mat Processed rock 125mm down Generally 800mm depth of construction
- 17. Construction Operations : Track details Plant and equipment 3 man geogrid handling squad Dozer Renewables Conference 14T roller 20T excavator 3 no 30T ADT Production Typically 125-200m per day Dependant on stone supply
- 18. Onshore Windfarm Construction and Operation Construction Operations : Track details Cut to fill track Criteria Renewables Conference Peat depths generally <1.0m CBR >5% Construction detail As raised rock 250mm down Earthworks balance Optimised volume and mass haul
- 19. Onshore Windfarm Construction and Operation Construction Operations : Track details Plant and equipment 2 no 14T LGP excavators 45T excavator and breaker 30T excavator and breaker Renewables Conference 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
- 20. Onshore Windfarm Construction and Operation Construction Operations : Borrow pits Consented borrow pits QR99 compliance Quarry plan Signage, drainage and fencing Renewables Conference Forestry clearance / Overburden strip Drilling and blasting operations Rock processing Concrete aggregates Floating roads Structural backfill Track surfacing Restoration
- 21. Onshore Windfarm Construction and Operation Construction Operations : Permanent drainage Permanent drainage design Drainage philosophy Track drainage Renewables Conference SUDS approach Watercourse crossings CAR registration and licensing Bridges generally >2m in bed Piped crossings generally <2m in bed Ecological constraints Water supply points
- 22. Onshore Windfarm Construction and Operation Construction Operations : Temporary drainage Temporary drainage design Guidance 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 Peat Control measures Temporary drainage plans Silt mitigation plans Water quality monitoring
- 23. Onshore Windfarm Construction and Operation Construction Operations : Concrete production Site batching plant and equipment Batching plant Mixer trucks Renewables Conference Establishment Layout Water supply Material deliveries Quality control Mix design Testing Quality control
- 24. Onshore Windfarm Construction and Operation Construction Operations : WTG bases Design type Assume 3.5MW with 78m hub height Submerged gravity base Cast in bolt set Renewables Conference 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
- 25. Onshore Windfarm Construction and Operation Construction Operations : Electrical works Electrical design P28 studies Grid code compliance Resistivity testing Renewables Conference Cable layout Electrical long lead items Transformers Cables Sub-station building Grid transformer delivery Cabling SCADA /communications system Energisation
- 26. Onshore Windfarm Construction and Operation Construction Operations : WTG installation Turbine delivery Traffic coordination Lay down areas and storage Renewables Conference Road condition monitoring and maintenance Turbine erection Lifting Plan Erection programme Turbine bolt grouting Electrical interface Energisation Commissioning
- 27. Onshore Windfarm Construction and Operation Construction Operations : PC Role PC 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