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Phases of Construction & Erection for Wind Power Project_03 09 2019

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Here are the details on 300MW Wind Power Project located in the Western Region of India presented by Gensol on the  various phases of construction & execution; starting from :

1)Wind resource assessment,
2)Site feasibility studies, 
3)Statuary & legal approvals required,
4)Civil & electrical works,
5)Quality & material inspection,
6)Post erection & monitoring etc.
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Phases of Construction & Erection for Wind Power Project_03 09 2019

  2. 2. Methodology – Execution of Wind Power Projects 2 Wind Resource Assessment Site Feasibility Studies (SFS) Technical Due Diligence (TDD) Statutory Permits and Approvals Erection & Commissioning
  3. 3. Wind Resource Assessment 3  WRA is the quantification of wind resources to compute parameters such as average wind speed, Wind energy density and average annual energy production. Figure: Stages of Wind Resource Assessment *AEP=Annual Energy Production, CFD = Computational Fluid Dynamics Stage I: Prospecting Stage II: Wind Measurement Stage III: Linear Wind Flow Model Based Estimation of AEP Stage IV: CFD Model Based Estimation of AEP Stage V: Loss & Uncertainty Estimation Bankable WRA
  4. 4. Pre-Feasibility & Prospecting 4 Mandatory during the pre feasibility of project site  Anecdotal evidences  Wind speed observation from wind deformation on objects and tress  Topology Siting Consideration 1. Transmission Capability  Substation Requirement  Existing Infrastructure  Compatibility  Point of Use Prospecting Process  Climatological study  Prospecting survey  Rating & Ranking the sites  Wind map & Upper Air Data 2. Wind Resource  Desirable Wind Speed (>7 m/s)  Long Term Average  Wind Profile 3. Permitting  Local/ State Authorities Clearance  Environmental Impact Study  Avian Impact Study 4. Land Use and Terrain  Agricultural Compatibility  Habitat Preservation  Road Access  Terrain Complexity, Roughness & Offshore
  5. 5. Erection & Commissioning (Civil) 5  Location should be obstacles free and have large space  Accessible for transportation of heavy machineries.  Co-ordinate verification should be done at site. Site Inspection  Witnessing of soil testing and samples collection at various depth during construction should be done.  Scrutiny of soil test reports to be done to check soil bearing capacity to rest the WTG foundation. Soil Testing
  6. 6. Erection & Commissioning (Civil) 6  Excavation is ensured within the provided bench mark & marked area.  Ensure earth work is done to the exact dimensions mentioned in the foundation drawing of the OEM.  Ensure bottom of excavation is leveled and shall be free of loose unconsolidated material Excavation Pre-stressed Cement Concrete  Ensure bottom of excavated surface lightly watered, thoroughly rammed, compacted & levels should be ensured before and after PCC .  Ensure PCC is laid as per the given specification & curing work for PCC  Ensure materials used for PCC (Cement, Sand, Aggregate & Water) comply with IS456 and other required standards.
  7. 7. Erection & Commissioning (Civil) 7  Ensure TMT bars of grade Fe-500 conforming to IS: 1786 is used.  Ensure test certificates from the manufacturers received and complies with the relevant IS specification .  Visual inspection on bars to be done.  Ensure lapping of rods are ok.  Ensure all steel reinforcement been accurately placed in position as shown in the drawing tied with 2 strands of 18 gauge GI annealed steel wire.  Ensure reinforcement is having cover as shown on the structural drawings.  Ensure electrical conductivity of reinforcement is ensured with welding in the indicated points in the relevant drawing. Reinforcement
  8. 8. Quality Inspection Of Concrete Ingredients 8  Ensure cement used are in sealed bag and compiles with Indian Standards.  Cement bags shall be stacked as per Standards.  It shall be stored in such a way as to allow the removal and use of cement in chronological order of receipt, i.e. FIFO (First in First Out).  Test certificates from the manufacturers should be obtained.  Cement stored in plant should be used before 3 months’ time from tests conducted. Cement  Ensure test certificate from registered laboratory or Government colleges and the source of coarse aggregate submitted for design mix is not changed during the concrete pour.  Ensure coarse aggregate conforms to IS : 383  Ensure the nominal maximum size as large as possible & within the limits specified in the design mix.  Conducting sieve test once every month to confirm the sand stocked in site Coarse Aggregate
  9. 9. Quality Inspection Of Concrete Ingredients 9 Fine Aggregate Sieve Designation as per IS 383  Ensure test certificate for sand from registered laboratory or Government colleges available and reviewed.  Ensure fine aggregate conform to IS: 383.  Ensure fine aggregate stacked carefully on a clean hard dry surface .  Ensure source of sand which has been submitted for design mix not been changed during the concrete pour. Fine Aggregate
  10. 10. Quality Inspection Of Concrete Ingredients 10  Ensure availability of water test report for water from registered laboratory or Government colleges and reviewed to confirm water compiles as per IS 456.  Ensure water used for mixing and curing is clean and free from materials deleterious to concrete or steel. Water Admixture  Ensure admixtures used comply with IS 9103.  Ensure admixture used is not stored in direct sun light and kept in sheds.  Ensure admixtures used before 1 year or as per manufacture specifications.
  11. 11. Verification Of Mix Design Report 11  Ensure detailed design mix report is obtained.  Ensure mix design report complies with IS10262.  Ensure design mix report includes detailed specifications of ingredients used.  Ensure compressive strength values of 7th and 28th day is mentioned in report. Trial Mix Verification  Ensure trail mix is made at site as per design ratio.  Ensure trial mixes prepared using coarse aggregates, sand, water and cement actually available at site.  Ensure adequate number of cube samples collected during trial mix.  Based on the trial mix cube reports results, The mix proportion of concrete shall be followed during the execution of castings. Mix Design Report
  12. 12. Site Observations 12 Concrete Pouring Foundation CompletedSlump Test Temperature Test Concrete Specimen Sampling
  13. 13. Post Concreting 13 De-shuttering  Ensure shuttering is removed after 24hrs from the finishing time of concrete  After de-shuttering, honeycombs in the concrete, if any, should be rectified  Ensure curing is done as per Standards.  Ensure curing is done using curing compound as per manufacture specifications or by wet gunny bags. Curing
  14. 14. Concrete Acceptance 14  Ensure number of samples tested comply with Indian Standards or as per OEM Standards.  Ensure test results of samples compiles with Indian standards for 28th day & OEM Specifications on intermediate date .  Witnessing the compressive test conducted .  Witnessing the Core test Or Non-Destructive Test. Acceptance as per IS 456 Clause 16.1
  15. 15. Core Test 15
  16. 16. Back Filling & Levelling of Location 16  Ensure backfilling is done as per specifications.  Ensure sides of the foundation is cleared .  Ensure backfilling is done in layers, thickness not exceeding 300mm.  Each layer should be properly consolidated / watered and compacted.  Minimum field dry density should be 1.8 g/cm3 for each layer.  Witnessing stone pitching or PCC laying over foundation backfilling as per OEM specification.  Witnessing demarcation and boundary stones laying .  Ensure proper drain facility to be done.  Ensure location is clean and levelled. Back Filling & Levelling of locations
  17. 17. 17  Number of Tangent, Cut point poles, Span Length, River crossings, road crossings , Rail way crossings , Span Length are being appropriately reviewed for the size of the poles as per IE rules & the size of the conductor.  Ensure proper design calculation is done in selecting the conductors.  Ensure Sag – Tension for all lines and sizes of poles used are designed by taking proper calculation.  Ensure Line poles are as per the IS Code no: 802 (Code of practice for use of structural steel in overhead transmission line towers) 33 kV Line Works Erection & Commissioning (Electrical) 33 kV Line Works
  18. 18. Incoming Material Inspection 18
  19. 19. Incoming Material Inspection 19 Material & Documentation  Visual inspection of materials during delivery.  Verifying the test certificates for the materials received and check its compliances.  Ensure components certificates complies with the following standards. Pole  RSJ pole : IS2062  Pre-stressed Concrete poles : IS78-1978 & IS2905- 1966  Tubular Pole should confirm to IS2713 Insulators  Polymer Insulators : IEC61109  Porcelain Insulators : IS731/71 Conductor  Al59 : IS398 PT.4  All ACSR : IS398 PT.2 Route Survey  Ensure shortest route is chosen.  Ensure minimum number of line crossings & road crossings.  Ensure all the line work and all the installations comply with the IE rules . Safe Clearances In Consideration For The Line Crossing As Per IE Rule 1956 Sl. No Nominal System Voltage 11-66 KV (m) 110-132 KV (m) 220 KV (m) 400 KV (m) 800 KV (m) 1 Low & Medium 2.44 3.05 4.58 5.49 7.94 2 11- 66kV 2.44 3.05 4.58 5.49 7.94 3 110-132kV 3.05 3.05 4.58 5.49 7.94 4 220 Kv 4.58 4.58 4.58 5.49 7.94 5 400 kV 5.49 5.49 5.49 5.49 7.94 6 800 kV 7.94 7.94 7.94 7.94 7.94
  20. 20. Incoming Material Inspection 20 Pole Marking  Ensure marking of the pole pits are in proper alignment.  Ensure cut point locations are marked after each 7 spans for other conductors and 6 spans for panther conductor.  Span length between maintained as per standards. Pole Pit Excavation  Ensure pole pit excavation depth is 1/6th of the pole height.  Ensure size of the pit dimension is as per Specifications.  Ensure excavation depth for stay pits are 4.5feet.
  21. 21. Incoming Material Inspection 21 Pole Selection & Erection  Ensure pole length, pole size and pole shifting should be done properly without any damages  Proper concerting, sufficient support should be provided during erection.  Ensure PCC is to be done in the bottom of the excavated pit . Pole Earthing, Coping & Identification  Ensure earthing done to all poles and insulators as per standards & earth resistance for poles are within 20 Ohms  Pole coping & muffing should be done as per specifications.  Ensure pole identification with proper standard like pole number, feeder details , SS details mentioned.
  22. 22. Incoming Material Inspection 22 Stay Rods  Ensure stay rod arrangements are as per standards and quality of stay rods are ok.  Ensure concrete for stay rods done as per specifications. Channel Fixing  Ensure stay provided at each cut point, angle points.  Ensure fabrication channel fixed with proper clamps.  Ensure all the hardware's and fasteners are provided and tighten properly.
  23. 23. Incoming Material Inspection 23 Insulator Fixing  Visual inspection done before insulator is fixed to observe any damages found  Ensure insulators are cleaned properly.  Ensure insulators installed as per standard procedures. Stringing  Ensure conductors used complies with Indian standards (IS 398)  Ensure quality of the components are as per standard & no damages found.  Ensure during stringing the conductor unrolled from the cable drum and laid as per procedures.  Ensure conductors tightened properly.  Ensure the sag is not more than 450mm in mid span area.
  24. 24. DP Yard Works 24 Double Pole Erection Activity Boundary Works
  25. 25. DP Yard Works 25 Yard Equipment Erection Earth Resistance Check Earthing Check Transformer & Other Accessories Erection
  26. 26. EHV Line Tower Works 26 EHV Tower Foundation & Member Erection
  27. 27. Pooling SS Works 27 Activities During Construction Of Pooling Substation  Land Purchasing.  Soil Resistivity Test.  Land or Zero level, FGL(Filled Ground Level) Marking By surveyor.  Structure & Transformer Foundations  Compound wall.  Earth mat-Grid  Structures & Transformers Erection  Equipment, Control & Relay Panel Erection,  Equipment, Control & Relay Panel Testing.  Battery Erection, AC,DCDB, PLCC, SAS Panel erection.  CIG Inspection for charging clearance.  Commissioning for Line & Transformer bay.  Control Room Constructions  Cable Trench
  28. 28. Pooling SS Works 28 Location Marking, Excavation & PCC Steel Binding & Raft Casting Column Casting & Curing Earth Mat Excavation for Laying Rod, Earth Mat Compacting & Core Test for Moisture Value
  29. 29. Pooling SS Works 29 Equipment Erection – CT/PT & Transformer Transformer Bushing Test Before Erection Cable Tray Fixing And Tack Welding Main Bus Stringing & Cable Tray Supporting Angle Welding
  30. 30. Pooling SS Works 30 Panel Erection At Control Room & Transformer Oil Filtration Power Evacuation Infrastructure Battery Erection & Control Room Building WTG Incoming Material Inspection/Verification
  31. 31. Damage Rectification At Site 31 Nacelle FRP Damaged Nacelle FRP Rectification Nacelle FRP after Rectification
  32. 32. Tower Preparation 32  Ensure proper cleaning of tower on both inside & outside.  Ensure sufficient cranes used for loading and unloading of segments from trailers during erection.
  33. 33. Tower Installation 33  Ensure all the erection activities are in progress according to OEM’s procedure  Ensure the presence of mechanical engineer of OEM .  Ensure proper orientation of Tower door of the T1 Tower Shell.  Ensure the safe torquing of bolts for every Tower to Tower Shell joints.
  34. 34. Nacelle Erection & Rotor Blade Assembly 34 Nacelle Erection Rotor Blade Assembly
  35. 35. Post Erection & Monitoring 35  Proper cable terminations & final torqueing  Proper routing and termination of control cables  Functional checks and DG commissioning should be ensured  Blade calibration for both pitching in and pitching out  Mechanical equipment's and grid parameters in the lCS of WTG will be ensured  Proper monitoring of WTG for few days after post commissioning The following points will be ensured post erection & monitoring:
  36. 36. Testing & Quality 36  Ensuring the quality standards of all project materials according to the applicable standards before dispatch clearances.  Witnessing the factory tests/type tests/functional tests of all project materials at their manufacturing facility to ascertain the materials quality.  HDG thickness should be checked for all hot dipped materials at the time of production as well as pre-installation time at site.  Site team shall make ensure the quality of all incoming materials as per the procedure/QAP before usage.  Testing & Quality inspection all project materials should be ensured during & after installation time.  Tightness of all machine parts like tower, nacelle ,hub and rotor should be checked twice by calibrated torque wrenches/other tightening tools & tackles. Temperature Test WTG materials for inspection
  37. 37. Plant Commissioning 37  Pre-commissioning checks should be carried out as per approved procedures.  Site team should ratify the quality of all project activities before commissioning.  Project manager & site team should concentrate on the safety practices and standards during works execution.  Plant handover to O&M team for lifetime of the project shall be done along with punch points and document handover.
  38. 38. Gensol is one of the leading consultants and system integrators for Solar Power Plants. We boast of a portfolio of over 6000 MW of Solar Photovoltaic Plants. Gensol is also a channel partner to Ministry of New & Renewable Energy and installs kW scale Solar Rooftop systems on a turnkey basis with more than 42 MW of cumulative installations across the country. The information contained herein is of a general nature and is not intended to address the circumstances of any particular individual or entity. Although we endeavor to provide accurate and timely information, there can be no guarantee that such information is accurate as of the date it is received or that it will continue to be accurate in the future. No one should act on such information without appropriate professional advice after a thorough examination of the particular situation. Email: solar@gensol.in | Web: www.gensol.in | Phone: +91 79 40068235 | Twitter: gensol_tweets Gensol Engineering Ltd | Gensol Consultants Pvt Ltd | Solarig Gensol Utilities Pvt Ltd Corporate Office A2, 12th Floor Palladium, Opp. to Vodafone House , Corporate Road, Prahladnagar, Ahmedabad, Gujarat. India - 380015