This document outlines the key phases and activities involved in constructing and commissioning a 300 MW wind power project. It discusses wind resource assessment, site feasibility studies, statutory permits, foundation works including soil testing and concrete pouring, tower installation, nacelle and rotor blade assembly, testing and commissioning activities. Quality inspection is emphasized for all materials and construction works. The document provides detailed guidance on construction methodology according to industry best practices and compliance with relevant standards.

1. 1
CONSTRUCTION & ERECTION PHASE PLAN FOR MW SCALE
WIND POWER PROJECT
300 MW WIND FARM PROJECT AT WESTERN REGION

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. 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. 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. 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. 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. 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. 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. 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. 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. 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. Site Observations
12
Concrete Pouring
Foundation CompletedSlump Test
Temperature Test Concrete Specimen Sampling

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. 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. Core Test
15

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
 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. Incoming Material Inspection
18

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. 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. 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. 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. 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. DP Yard Works
24
Double Pole Erection Activity
Boundary Works

25. DP Yard Works
25
Yard Equipment Erection
Earth Resistance Check
Earthing Check
Transformer & Other Accessories Erection

26. EHV Line Tower Works
26
EHV Tower Foundation & Member Erection

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. 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. 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. 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. Damage Rectification At Site
31
Nacelle FRP Damaged Nacelle FRP Rectification Nacelle FRP after Rectification

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. 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. Nacelle Erection & Rotor Blade Assembly
34
Nacelle Erection Rotor Blade Assembly

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. 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. 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. 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