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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
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
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
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
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
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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
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
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
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
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
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
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
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
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
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
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
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
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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
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
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
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
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
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
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
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
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
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