Tortonbanks

Belgium view map

C-Power - SENVION
OEM
Engineering Design (turbine and transition piece),Grid Integration & Compliance
Electrical, Communication & SCADA, Works Supervision
325 MW
Feb08 - Mar12

Customer & Stakeholders

“C-Power”, a consortium of Belgium and other European companies.

The project is located in the north see approximately 30 km north from Oostende where the onshore site was based. The site water depth is between 12m and 27,5m and the occupied area is 19,84 km2. The task consisted in supervision and trouble shooting of the commissioning works with special emphasis on communication, radar & navigation signals, webcams, documentation and field work instructions

Challenge

In generally the see environment the whether and the accessibility of the turbines by itself was a challenge. The other main challenges in this project were methodology, onshore-offshore work organization and site coordination. The coordination of works was also a challenge as team shifts demand constant training and tight supervision of works. Finally the challenge of the industry being still inexperienced, balancing between performing activities onshore (downside of having a long waiting time for transport, installation etc) or performing the activities offshore (later on but expensive and more risky).

The Plan

New methodology and works organization needed to be introduced to cope with the works onshore-offshore. Everything needed to be well prepared and double checked, personnel needed constant training before being shipped offshore. Because of work shifts and training needs on the teams (installation, commissioning, etc.) the supervision and training activities needed strong reinforcement.

Success

The results where very good with slight schedule over-run due to whether (waves, rain and wind) conditions and some budgets updates. Mostly important the Customer was satisfied with the overall team and project performance and execution.

Ancora

Portugal view map

Senvion
OEM
Grid Integration & Compliance,Construction Management
Electrical, Civil, Project Management, Communication & SCADA
170 MW
Sept14 - Nov16

Customer & Stakeholders

VENTIVESTE – Consortium led by GALP (34%), Martifer (31%) and Enersis (30 %), EFACEC (2%) and REpower (1%).    

Senvion S.A. (called REpower Systems SE until 2014) was a German wind turbine manufacturer founded in 2001 in Germany, delivering the full EPC supply including over 100 turbines.

Challenge

The consortium won the 2nd phase of the Portuguese Public Government tender, consisting in 400 MW distributed through several wind farms including the creation of clustered production facilities in remote regions. The project consisted as implementation of strategic development for the parties.

The development included permitting, grid access rights for several wind farms. Some areas had challenging environmental requirements including construction constrains for protected species and areas, multiple interfacing and crossing with public infrastructure, etc. Grid access had the challenge of buildling  a 400 kV substation and overhead line for interfacing the TSO the company REN. Additionally, several other substations and overhead lines needed to be built to interconnect the different projects “Sernancelhe” and “3-Marcos”.

The local Senvion team, took responsibility for the majority of BoP works and turbine supply, including contracting and supervision. The local Portuguese Team needed to ramp up and find a solid combination of profils and own personnel to cope with the management of the 4 projects running in parallel and in a tight deadline.

The Plan

The plan consisted in putting together a motivated and experienced team, finalize the detail engineering phase, execute the contracting scope definition with the contractors, start construction works as soon as possible in order to avoid the barrier of works during constrained season in order to comply with regulator deadlines.

Perform all pre-studies necessary to kick start the engineering as well as establish high level coordination with TSO specially in regard to grid performance and integration.

Find and engage experienced site supervision team to cope with high pressure and quality requirements from the customer. A difficult challenge would also be the  safety management, not only during peak work execution but especially before start of each activity. With 4 projects going almost simultaneously in remote and disconnected areas, the amount of documentation (procedures, insurances, safety training, etc) to be verified and checked daily for workers and companies going in and out of the activities was tremendous.

Results

In order to serve project tight schedule construction started soon, however that would create expected contractor bottlenecks regarding availability of workers and machinery tied in other projects. That challenge could be managed and solutions for acceleration were found.

Initially there were a number of delays caused by activities not starting in due time,  documentation submittal and approval process was taking too long and cousing delays. In many cases the worker`s aptitude and registrations could not be verified and it caused construction delays. After a slow start the processes was accelerated and the companies were advised to pre-schedule submittals of documentation and avoid late approval and starts.

The supervision team was very experienced and could coordinate and antecipate  contractor issues, including start of activities and sustain high performance and quality levels. The works could generally be executed in quality, in budget and in time.

Strong push and motivation from the team contributed decisively to accelerate and reduce accumulated delays during the 2 years of construction and challenges.

Finally, and mostly important the customer could successfully celebrate bringing this big project online and profit for the long generating value it creates.

Vientos del Secano

Argentina view map

Envision
Owner
Grid Integration & Compliance,Engineering Design (BoP),Construction Management
Electrical, Civil, Communication & SCADA, Project Management, Works Supervision
50 MW
Oct18 - Nov20

Customer & Stakeholders

 

Envision – the Envision Group is a world leading provider of wind power technology and energy storage solutions

Envision Argentina – Local subsidiary of the Envision Group

Challenge

As a part of its strategic development, Envision acquired the development rights of the project Vientos del Secano in the province of Bahia Blanca in Argentina.

The project was the company`s biggest wind farm in south America, consisting in 50 MW. The scope included the full BoP works and a transmission substation for the utility TRANSBA.

The tight overall deadline from the regulator CAMMESA set the frame or the entire development and construction process, making extremely challenging. Additionally the project was being developed at the same time as other local projects, increasing the overall resource bottleneck on all parties. To add up to the total challenge the main contractor was having a series of difficulties in the country and finally gave up the site and the works, leaving it all up to owner to reach the final objective.

The project would also be hit by the world pandemic affecting all works.

The Plan

The plan consisted in building up a local project team, setting up the processes, the roles and responsibilities, the supply chain, reporting and project steering.

Permitting and grid interfacing engineering needed to be urgently addressed as the TSO for the 123 kV substation demanded a complex decision process and management.

Following the works abandonment of the main contractor, a sudden built up of own resources would be necessary in order to pick up and own the works, supplies and materials as they were left.

Commissioning procedures needed to be adapted and ad-hoc creative solutions put in place to deal with limitations of the COVID crisis and the travel restriction to and from Bahia Blanca area.

Results

In order to serve project timeline and after long and challenging interface discussions with the TSO, fast decisions were taken, leading to increased project scope (extra switching station).

Additional Engineers and Site Managers were hired to manage all subcontractor`s works, left adrift by the leaving contractor.

Specially rented Motorhomes helped minimizing COVID impact, and housed technicians arriving for construction and commissioning. Local travel restrictions would otherwise require long quarantines before entering the region / site.

Remote commissioning procedures needed to be developed and implemented to allow an international team to support the activities on site.

Strong push from all sides contributed decisively to accelerate and reduce the delay expected due to all accumulating challenges.

Finally, and mostly important the customer could successfully celebrate bringing this important milestone projects online and enjoy the returns the asset operation.

Vliessingen

The Netherlands view map

EPZ - SENVION
OEM
Engineering Design (BoP),Grid Integration & Compliance
Project Management, Electrical, Communication & SCADA
12,3 MW
Dez11 - Mar12

Customer & Stakeholders

 

EPZ (Elektriciteits Produktiemaatschappij Zuid-Nederland) the Electricity Production Company South-Netherlands, the operator of the coal- and nuclear power plants located in Borssele in the Netherlands.

OVET – Terminal Port Administrator in Vliessingen, administrating coal storage area

Senvion S.A. (called REpower Systems SE until 2014) was a German wind turbine manufacturer founded in 2001 in Germany, delivering the full EPC supply including the 2 x 6M turbines.

Challenge

The customer approached REpower to deliver a full EPC turn-key project at a harbour location, in the middle of a coal storage area, an area administered by OVET an external 3rd party company. This consisted in the first challenge, install big 6M turbines and perform infrastructure works (access, transport, craning, cabling, foundations) in the middle of a densely covered area with huge 50m height pills of coal and administered by a 3rd party. Any clearance of space would not only take days but also have a considerable financial spending for project. The ground had a covering layer of asphalt for protection of underground infiltration and pollution. Any work needed to critically manage soil pollution risk. One of the biggest challenges however was to plan the execution of the wind farm works around the daily normal operation of the harbour / coal power plant, any project setback could jeopardize the energy delivery of the power plant. Electrically there was also a considerable risk in connecting two (2) powerful turbines to the somehow “weak” 30 kV harbour grid, it could affect the cranes and other used heavy machinery, even the testing of the turbines could impact the stable operation of the entire harbour and power station. On top of all these challenges, it was REpower`s first full scope project with BoP outside of Germany entirely managed by an internal team. The challenges and risk were big as the project moved into execution.

The Plan

When our customer approached us the challenge was quite clear. Our job consisted in supporting him with a solid, safe design and planning, and execute perfectly. Our team managed the engineering design both civil and electrical, and provided the customer for a basis for a safe planning. On the engineering side the tasks included works specification, tendering, negotiation, contracting. On the project management side the tasks included planning coordination, execution supervision and final taking over.

To minimize impact and risk, the plan consisted in making just enough space between the big pills of coal for the unavoidable access, foundation work and crane assembly, thus minimizing impact inside critical coal area. The plan also considered safeguarding the existing protective asphalt layer, therefore planned for directional underground drilling for the cable trenches. 3 holes over 400m each were necessary to turbines, station and even power an auxiliary building nearby. Long PVC ducting works were performed outside critical area, and then pulled into final position in 1 attempt. Medium voltage, communication, low voltage power supply cables would would then be installed into the PVC ducts. The station and grid operation parameters were carefully evaluated and selected with the local grid operator (Delta), so that testing and operation ramp up had minimal impact on local grid stability.

Implement on site daily activity coordination as at times more than 5 subcontractors would need to work in parallel inside the critical area, and confined space.

Results

The choices made during design enabled a solid planning a good start into execution. It helped our customer keeping the coal power plant operating and minimized the impact on OVET`s moving pills of coal. During drilling the team faced last minute uncertainties as exact information about dept of old buried cables and the risk of drilling through them arose. The results could have been disastrous and the impact on the harbor area and project huge. Still the team managed with help of local sub-contractor knowledge to overcome that barrier and managed the uncertainty. There were minor schedule delays due to whether (snow, rain and ice) conditions but finally the project was successfully installed and both turbines and power plant could operate stability. Mostly important our customer celebrated the great achievement of installing 2 big turbines in the middle of a coal yard and manage to bring it successfully into full operation.

Dzilam

Mexico view map

Envision
Owner
Grid Integration & Compliance,Engineering Design (BoP),Construction Management
Electrical, Civil, Communication & SCADA
70 MW
Mar17 - Oct18

Customer & Stakeholders

 

Vivenergia – is a developer established in 2012 focused on development, financing and construction of renewables based in Mexico.

Envision – the Envision Group is a world leading provider of wind power technology and energy storage solutions

Challenge

As a part of the strategic execution, Envision acquired a majority stake in the project pipeline of Vivenergia, including the project Dizlam in the Yucatan peninsula in Mexico.

The project had several first ones: first project in Yucatan, first project from the developer transitioning into construction, first project connecting with the new grid code, first Envision full BoP project overseas as an owner, first project under coordination of the new Hamburg Centre of Excellence (COE) office.

The scope included a complete update of an existing TSO substation, the construction however needed to happen maintaining service to existing load centres and arriving overhead lines.  Integration of the project into CENACE (Dispatching and regulator) would also need to be well managed as it was the first wind power plant in Yucatan Peninsula.

Additionally, project financing and due diligence was performed in parallel with the initial stages of construction, adding up the challenges.

consequências 1) a contaminação so sub-solo ou 2) a paragem da operação de transporte de carvão para a central.

The Plan

The plan consisted in building up a local project team, setting up the processes, the roles and responsibilities, the supply chain, reporting and project steering.

Permitting engineering needed to be urgently addressed as the TSO 115kV substation had long revision times. Additionally, there were 70 km of overhead line up to the PCC which also would need complex permitting. Finally

Grid code change would require also fast solutions and modification of existing engineering drawings, integration of a Statcom and the development of special SCADA control functionalities.

Integration of the power plant into CENACE needed to be subcontracted to the wind farm substation control and protection supplier, enabling the the turbine`s SCADA to act as data supplier.

Success

Analysis of existing engineering / permitting enabled fast decisions to hire a separate engineering team within the TSO and accelerate works execution on the grid substation. Delays in this substation directly and strongly impacted the project.

Another crucial decision was subcontracting the integration of the power plant into CENACE`s dispatch centre, that enabled the team to focus completely on developing the new required functionalities for the grid code compliance.

Very fast electrical substation modifications enabled Statcom integration and enhance of overall performance. Failing to be compliant meant a huge risk for the asset and a potential tremendous financial impact. A strong push from all sides contributed decisively to accelerate and recover delays of inexperience from all parties.

Finally, and mostly important the final customer could successfully celebrate bringing such an important milestone projects online and transition it into operation.