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Michigan Energy Forum
March 1, 2012

Topic:     How a Wind Farm Gets Built – Construction phase
Agenda

•   From Development to Selecting a Contractor
•   Design/Permitting/Contractor Coordination
•   Key construction aspects
•   Construction order and pictures




                                                 2
Typical Schedule
   Project Development


                                Permitting


                             Design



                         Procurement



                                                Construction



Start              Year 1              Year 2             Year 3
                                                  3
Selecting a Contractor




 Request for           Negotiations
  Proposal                 (Liquidated         Execute
 (Experience, Price,
                       Damages, Limits of        the
                       Liability, Insurance,
   Safety Record,         Price, Force
                                               Contract
   Balance Sheet)            Majeure)




                                                          4
Design and Work Plan Coordination




                                    5
What Is A Wind Farm?

•   A wind farm is an energy project consisting of:
     – Wind Turbines
     – Foundations
     – Roads
     – Underground Electrical Collection System
     – Substation & Transmission
     – SCADA System
     – O&M Facility




                                                      6
Permitting: Most Common for Wind
    Projects

•   National
     – FAA Review
     – Endangered Species Act Review
     – Bald Eagle Protection Act
     – Migratory Bird Protection Treaty
•   State
     – Historical Preservation
     – Stormwater Discharge
     – Highway Occupancy
     – Michigan Tall Structures Act
•   Local
     – Conditional Use Permit
     – Building/Road/Construction permits
•   Most other permits avoided by careful siting
                                                   7
Procurement: Long-Lead Time Items




Wind Turbines: 6 - 9 months          Cables: 0.5-1 Year, High Theft


                              •   Remaining Materials: Typically Within
                                  20 Weeks, Significant Increases in
                                  Concrete, Steel and Copper



   Switchgear: 1 Year+
                                                    8
Construction

               •   Can Be Quickest Part of Project
                   Development

               •   About Half Involve Lower-Visibility
                   Ground Work

               •   Wind Turbine Erection Can Take
                   Only A Few Days Per Turbine

               •   Turbines Often Do Not Run for
                   Weeks or Months After Erected While
                   Balance of Plant Completed

               •   Wind, Weather Can Slow
                   Construction
                                        9
Project Access Roads

•   Wind Turbine Access During
    Construction and Operation

•   Crane Access

•   Typically 40 ft Wide During
    Construction
     – Reduced to 16 - 20 ft Wide
       During for Operations

•   Final Width Graveled, Temporary
    Shoulders Just Compacted




                                      10
Example Access Road




                      11
Wind Turbine Foundations
                  Design Driven By
                    - Wind Loading
                   - Soil Conditions
               - Seismic Requirements


         Mat Foundation                  P+H Foundation




                               10 feet
                                                  30 feet
            50 feet

                                         12
Example Wind Turbine Foundations


       Mat Foundation         P+H Foundation




                                           13
Wind Turbines “by the numbers”
•  Blades (3)
     – Length per Blade: 138’                                                                                      
     – Weight per Blade: 13,700 lbs
• Hub (Red)
     – Weight: 50,700 lbs
• Nacelle
     – Length: 29’
     – Width: 12’
     – Height: 8’ high
     – Weight: 126,000 lbs
• Tower Sections
     – Top, Mid(s) Base
     – Lengths very per Section from 50’‐70’
     – Weight for Tower Assembled: 520,000 lbs
• Foundation
     – Base and Pedestal:  384 yards of concrete (40 concrete Trucks)
        1.4 million lbs of concrete
     – Weight of Reinforcing steel : 70,000 lbs
TOTAL TOWER WEIGHT:     370 TONS
                                                                                                                      14
Wind Turbine Rotor

 Vestas V82




GE 1.5MW sl
                     15
Wind Turbine Nacelle – Vestas V82




                                    16
Wind Turbine Erection




                        17
Looking down from the top of a
100 meter tower . . .




                                 18
Electrical Collection System

                       •   Interconnect Each Wind Turbine
                           to Substation

                       •   Collect Energy Generated




                                                            19
Project Substation and Transmission
•   Collects All Generation
•   Increases Power to Transmission
    Voltage
•   Sends Out on Grid
     – 40 kV (Thumb distribution)
     – 120 kV, 345 kV (Thumb
       transmission)




                                      20
O&M/SCADA Center

                   •   Larger Projects Require
                       On-Site Operations and
                       Maintenance Facility

                   •   Can Be New Buildings or
                       Existing Local Buildings




                                                  21
Q&A




      22
Appendix




           23
Wind Technology
        Blade Pitch System                              Gearbox & Generator
        • Adjusts angle of the blade for                • 3 stage gears increase rpm of rotor shaft (~12rpm)
        braking & optimization                          to high rpm (~900rpm) of generator which converts
        • Electric motors or hydraulics                 mechanical energy into electrical energy




                                                                                               Nacelle
Rotor Blades
• Made of glassfiber or carbon fiber
• Up to 40 meters in length
• LM Glassfibre or OEM
                                                                                    Alstom Ecotecnia 100
                                                                                    shown in picture



                 Tower                                        Yaw          Power Converter & Transformer
                 • Between 40 to 100 m in height                           • Converts DC to AC for the grid
                 • Manufactured in sections(rolled steel)                  • Step up turbine voltage


                                                                                                         24
330’ off the ground!




Monroe Stakes 660’   Wind Turbine 330’   Transmission Tower 150’


                                                            25
Typical 1.5MW Turbine




                        26
Developmental Factors – the site

Focus is different then other projects
Work Site-
Typical work site size is 80+ square acres


Collection Systems vs Field Tile-
On average 2500 repairs/park.
Documented with photos and GPS


Crop Damage-
Both during construction and the next planning
season


Property Lines-
100 years of assumed “property boundaries are
discovered.
Actual property lines always a surprise to everyone.



                                                       27

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March 2012 - Michigan Energy Forum - Carmen Bender

  • 1. Michigan Energy Forum March 1, 2012 Topic: How a Wind Farm Gets Built – Construction phase
  • 2. Agenda • From Development to Selecting a Contractor • Design/Permitting/Contractor Coordination • Key construction aspects • Construction order and pictures 2
  • 3. Typical Schedule Project Development Permitting Design Procurement Construction Start Year 1 Year 2 Year 3 3
  • 4. Selecting a Contractor Request for Negotiations Proposal (Liquidated Execute (Experience, Price, Damages, Limits of the Liability, Insurance, Safety Record, Price, Force Contract Balance Sheet) Majeure) 4
  • 5. Design and Work Plan Coordination 5
  • 6. What Is A Wind Farm? • A wind farm is an energy project consisting of: – Wind Turbines – Foundations – Roads – Underground Electrical Collection System – Substation & Transmission – SCADA System – O&M Facility 6
  • 7. Permitting: Most Common for Wind Projects • National – FAA Review – Endangered Species Act Review – Bald Eagle Protection Act – Migratory Bird Protection Treaty • State – Historical Preservation – Stormwater Discharge – Highway Occupancy – Michigan Tall Structures Act • Local – Conditional Use Permit – Building/Road/Construction permits • Most other permits avoided by careful siting 7
  • 8. Procurement: Long-Lead Time Items Wind Turbines: 6 - 9 months Cables: 0.5-1 Year, High Theft • Remaining Materials: Typically Within 20 Weeks, Significant Increases in Concrete, Steel and Copper Switchgear: 1 Year+ 8
  • 9. Construction • Can Be Quickest Part of Project Development • About Half Involve Lower-Visibility Ground Work • Wind Turbine Erection Can Take Only A Few Days Per Turbine • Turbines Often Do Not Run for Weeks or Months After Erected While Balance of Plant Completed • Wind, Weather Can Slow Construction 9
  • 10. Project Access Roads • Wind Turbine Access During Construction and Operation • Crane Access • Typically 40 ft Wide During Construction – Reduced to 16 - 20 ft Wide During for Operations • Final Width Graveled, Temporary Shoulders Just Compacted 10
  • 12. Wind Turbine Foundations Design Driven By - Wind Loading - Soil Conditions - Seismic Requirements Mat Foundation P+H Foundation 10 feet 30 feet 50 feet 12
  • 13. Example Wind Turbine Foundations Mat Foundation P+H Foundation 13
  • 14. Wind Turbines “by the numbers” • Blades (3) – Length per Blade: 138’                                                                                       – Weight per Blade: 13,700 lbs • Hub (Red) – Weight: 50,700 lbs • Nacelle – Length: 29’ – Width: 12’ – Height: 8’ high – Weight: 126,000 lbs • Tower Sections – Top, Mid(s) Base – Lengths very per Section from 50’‐70’ – Weight for Tower Assembled: 520,000 lbs • Foundation – Base and Pedestal:  384 yards of concrete (40 concrete Trucks) 1.4 million lbs of concrete – Weight of Reinforcing steel : 70,000 lbs TOTAL TOWER WEIGHT:     370 TONS 14
  • 15. Wind Turbine Rotor Vestas V82 GE 1.5MW sl 15
  • 16. Wind Turbine Nacelle – Vestas V82 16
  • 18. Looking down from the top of a 100 meter tower . . . 18
  • 19. Electrical Collection System • Interconnect Each Wind Turbine to Substation • Collect Energy Generated 19
  • 20. Project Substation and Transmission • Collects All Generation • Increases Power to Transmission Voltage • Sends Out on Grid – 40 kV (Thumb distribution) – 120 kV, 345 kV (Thumb transmission) 20
  • 21. O&M/SCADA Center • Larger Projects Require On-Site Operations and Maintenance Facility • Can Be New Buildings or Existing Local Buildings 21
  • 22. Q&A 22
  • 23. Appendix 23
  • 24. Wind Technology Blade Pitch System Gearbox & Generator • Adjusts angle of the blade for • 3 stage gears increase rpm of rotor shaft (~12rpm) braking & optimization to high rpm (~900rpm) of generator which converts • Electric motors or hydraulics mechanical energy into electrical energy Nacelle Rotor Blades • Made of glassfiber or carbon fiber • Up to 40 meters in length • LM Glassfibre or OEM Alstom Ecotecnia 100 shown in picture Tower Yaw Power Converter & Transformer • Between 40 to 100 m in height • Converts DC to AC for the grid • Manufactured in sections(rolled steel) • Step up turbine voltage 24
  • 25. 330’ off the ground! Monroe Stakes 660’ Wind Turbine 330’ Transmission Tower 150’ 25
  • 27. Developmental Factors – the site Focus is different then other projects Work Site- Typical work site size is 80+ square acres Collection Systems vs Field Tile- On average 2500 repairs/park. Documented with photos and GPS Crop Damage- Both during construction and the next planning season Property Lines- 100 years of assumed “property boundaries are discovered. Actual property lines always a surprise to everyone. 27