Download Report

CONSTRUCTION OF
WWP IN NEW AND
EMERGING MARKETS:
GES EXPERIENCE
APRIL 2015
JOSE LUIS SEVILLANO - GLOBAL KEY ACCOUNT MANAGER
AYDIN ALTUNORDU - GES TURKEY COUNTRY MANAGER
GLOBAL MARKET LEADER
IN CONSTRUCTION AND SERVICES
FOR WIND & SOLAR
11,300 MW BOP
22,600 MW INSTALLED
12,600 MW O&M
200.000 BLADE DAMAGES SERVICED
30.500 BLADES REPAIRED
2 | Construction of WWP in New & Emerging Markets|
280 MW EPC
230 MW O&M
30 YEARS IN ENERGY
280 MW EPC
230 MW O&M
3 | Construction of WWP in New & Emerging Markets|
11,300 MW BOP
22.600 MW INSTALLED
12,600 MW O&M
YOUR PARTNER THROUGH THE
WHOLE VALUE CHAIN
4 | Construction of WWP in New & Emerging Markets|
PARTNERING WITH THE BEST
As an independent service company, GES works with most of the main
players in the renewable energy sector. This has provided us with valuable
experience and lessons learned for future projects.
5 | Construction of WWP in New & Emerging Markets|
GES IN TURKEY
• GES started its activities in Turkey in October 2011, with the O&M contract for the Soke
wind farm (30 MWs) for Gamesa.
• In 2013, we carried out our first Turbine Installation project, the Senkoy wind farm for
Alstom.
• Turbine installation works have been executed by international teams with local support
whereas O&M services are provided mainly with local technicians.
• We are also providing blade services upon request with our German WKA teams.
• GES Turkey has currently a Country Manager (Mr. Aydin Altunordu) and 12 O&M
employees, all of them Turkish citizens except team leaders.
• We opened our new office in İstanbul in Feb 2015.
6 | Construction of WWP in New & Emerging Markets|
GES NEW OFFICE IN ISTANBUL
GES Yenilenebilir Enerji Ltd Sti.
Barbaros Mah. Kardelen Sok.
Palladium Tower No:2 K:10
34746 Atasehir, Istanbul, Turkey
7 | Construction of WWP in New & Emerging Markets|
O&M EXPERIENCE IN TURKEY
KIYIKOY WF
14 WTGs/ G9X / 28 MW
SOKE WF
15 WTGs/ G9X /
30 MW
MANDRABABA WF
10 WTGs/ G9X / 20 MW
8 | Construction of WWP in New & Emerging Markets|
ATIKBELEN WF
14 WTGs/ G9X / 28 MW
CERCIKAYA
19 WTGs/ AW3000 / 57 MW
GES IN TURKEY - TURBINE INSTALLATION
KIYIKOY WF
14 WTGs/ G9X / 28 MW
SENKOY
3 WTGs/ Eco 110 / 9 MW
9 | Construction of WWP in New & Emerging Markets|
GES IN TURKEY – OPPORTUNITIES I
• Electricity demand growth rate : 5 -7% in the last 5 years
• Political support for renewables due to high dependence
on energy imports
• Excellent wind and solar resources located in large
consumption areas
• New unlicensed power generation regulations
• There is an opportunity to develop local installation teams
and serve the region, not only Turkey, with lower costs in
the mid-term.
10 | Construction of WWP in New & Emerging Markets|
GES IN TURKEY – OPPORTUNITIES II
• Future market : National target for 2023 is 20.000 MW,
whereas E2014 installed Wind capacity is 3.762 MW.
• Current market : As of 2014, total number of licensed wind projects
(in operation + under construction + not started yet ) = 283 Nos (total
capacity appr. 10.000 MW)
• Mid term market : Until 2018, TEİAŞ announced to award 3.000 MW
additionally.
• Need for experienced services : These projections will result in a big
demand for qualified, experienced and professionally managed field
resources.
11 | Construction of WWP in New & Emerging Markets|
GES IN TURKEY –TO BE IMPROVED
• Need for a more stable legal basis : regulations are changing, the
market is not yet legally stabilised. This slows down development,
especially foreign investors.
• Bureaucracy and complex licensing process, although it has been
eased with the new Electricity Market Law issued in March 2013.
• Lack of grid capacity. Until now TEIAS has confirmed connection
capacity of around 13 GW of wind farms and has declared that the
grid in 2023 will be able to support the 20 GW target.
• Insufficient qualified local manpower : There will be a requirement
for approximately 2.250 wind service technicians in 2023 in Turkey,
as per 20 GW targets.
12
| Construction of WWP in New & Emerging Markets|
CHALLENGES IN WIND
PROJECTS
MAIN CHALLENGES NOWADAYS
1.
2.
3.
FINANCING
•
Finding contractors with ability to provide financial and technical
warranties
•
Assure top quality of works
•
Contractors able to support and close the project-finance
DESIGN
•
Foundation design
•
Roads and earthworks optimization
•
Electrical networks and cables optimization
•
Grid code compliance
EXECUTION
•
Management of various contractors
•
In-time execution according to the schedule
•
Closing interfaces that occur between BOP and turbine erection
contractors
•
Management of local society
14 | Construction of WWP in New & Emerging Markets|
A COMMON SITUATION NOWADAYS…
Bank
We want the least
risky project with
your maximum
commitment!
Invest your money
and then we see…
Government
Investor
Subcontractors
We know how to
do it, just give us
the job!
15 | Construction of WWP in New & Emerging Markets|
This is our land!
We must control
everything!
Locals
HOW WE MANAGE IT?
GES delivers quality projects, supporting them with its financial solidity and technical experience, in the
most complex circumstances all around the world.
16 | Construction of WWP in New & Emerging Markets|
PROJECT ANALYSIS
In every new project in a new country the BOP Contractor must launch a Project Analysis, examining
the following issues:
COUNTRY LAWS
UTILITY REQUIREMENTS
HEALTH & SAFETY COUNTRY REQUIREMENTS
LOCAL PROJECT CIRCUMSTANCES
SOIL CONDITIONS
RELIABILITY OF KEY CONTRACTORS AND SUPPLIERS. PARTNERSHIP.
INTERCONNECTION AND SUBSTATION ENGINEERING
LOCAL AND NON-LOCAL MIX. VISA
LOGISTICS AND PROJECT SCHEDULE
17 | Construction of WWP in New & Emerging Markets|
ADMINISTRATIVE ANALYSIS
Legal issues
Financial issues
• Corporate and commercial law. Set up of local company.
• Currency
• Logistics. Imports, Customs
• Warranties and contractual requirements
• H&S legislation.
• Interaction with project’s financing organizations
• Recruitment. Employment legislation and new hires.
• Parent company support
Community aspects
Contractors & Suppliers
• Relationship with local municipality
• Thorough market research
• Maximization of involvement of the community
• Reliability and experience (even if no wind related)
• Agreements for land leasing and activities during the
project’s execution
• Partnership: JV, Consortium,…
• Interaction with the investor to find the best approach
18 | Construction of WWP in New & Emerging Markets|
TECHNICAL ANALYSIS
Soil conditions
Foundation design
• Geotech analysis
• Geotech analysis.
• Selection of road design and hardstand solution
• Selection of best suited option:
• Consider weather influence on the plan
• Spread foundation
• Cement, lime column
• Warranties and Insurance
• Quality assurance
Interconnection & Grid code compliance
Logistics and planning
• Complete analysis required: voltage drop, power losses,…
• Ensure all permits are in place.
• Utility requirements. This may take long sometimes.
• Frequent planning update to ensure compatibility between
BOP contractor, transport, cranes and installation company.
• Clarify which company is responsible for what.
• Interaction with the investor at all time to agree the best
planning update when needed.
19 | Construction of WWP in New & Emerging Markets|
SOME EXPERIENCES IN
NEW MARKETS
20 | Construction of WWP in New & Emerging Markets|
TALINAY PROJECT (CHILE)
90 MW. VESTAS 1,8 MW, 2 MW & 3 MW
2012-2013
21 | Construction of WWP in New & Emerging Markets|
TALINAY
CHALLENGES
• SPECIAL PROJECT. It was the largest wind farm to be built in Chile in 2012, with special
focus by the investor and political authorities
• NEW COUNTRY FOR GES. It was our first experience in the country.
• INCREASED COMPLEXITY. A complex project of 90 MW in total, combining installation of
different WTGs of 1.8 MW, 2 MW & 3 MW. Also, it included a 220/30 kV SUBSTATION and
a 220 kV Overhead line.
• LACK OF RESOURCES. There was a significant lack of resources (manpower and materials)
in the region
• CONCRETE SUPPLY ISSUES. No concrete plants around
• LICENSING INVOLVED. HV line designed to cross over the “Panamericana” (main highway
in South America) with GES in charge to manage all the licenses
22 | Construction of WWP in New & Emerging Markets|
TALINAY
SOLUTIONS
• COUNTRY ASSESMENT: Thorough research was performed during the tendering process to get knowledge
of: (available machinery, local providers, engineering companies, seismic laws, utility requirements, health &
safety standards).
• ENGINEERING NETWORK: By setting up a partnership with local engineering, GES got deeper knowledge
concerning utility and country requirements.
• TO GET QUALIFICATION BY THE LOCAL UTILITY (TRANSELEC). Through this approach, better access to
utility requirements & key people (decision makers) was achieved.
• TEMPORARY CONCRETE PLANT ON SITE & 3 DIFFERENT STEEL SUPPLIERS. Both decisions allowed to
speed up foundations execution. 45 Foundations were completed in 2 months (rate 5.5/week).
• TO SPLIT WINDFARM IN 4 BIG AREAS, AND TO OUTSOURCE TWO LOCAL CONTRACTORS FOR
CONSTRUCTION OF ROADS, TRENCHES & HARDSTANDS.
• 3 INDEPENDENT TEAMS FOR WTG INSTALLATION. (Cranes & manpower).
• LARGE UTILIZATION OF RESOURCES. There were more than 200 workers involved in several stages of
project.
23 | Construction of WWP in New & Emerging Markets|
TALINAY
OUTCOME
• 0 ACCIDENTS.
• AHEAD OF SCHEDULE: GES enhanced the contractual planning, completing roads, MV grid,
Substation, foundations and Overhead line, 45 turbines erected, in second week of December 12,
starting in July 12 (5 months).
• TURBINE INSTALLATION: Erection of WTGs was completed in 1,5 months. (rate 6,5/week).
• HIGH REPUTATION WITHIN THE COUNTRY, AFTER INAUGURATION OF THE PLANT BY CHILEAN
PRESIDENT. This opportunity was used to emphasize the benefits of renewable energy to the whole
country.
• GES HAS BECOME LEADER IN RENEWABLES IN CHILE, BEING CURRENTLY INVOLVED IN 4 MORE
PROJECTS, WITH A TOTAL POWER OF 160 MW IN ONE SINGLE YEAR.
24 | Construction of WWP in New & Emerging Markets|
TALINAY
MAIN ACCOMPLISHMENTS
• Excavation of Foundations day and night,
24/7. 45 foundations in 8 weeks.
• 400 m3 of concrete as an average on
each foundation. Total 19,500 m3, as a
10-storey building made entirely of
concrete
25 | Construction of WWP in New & Emerging Markets|
• Concrete factory on site, fully equipped to work
at night. Foundations were in the critical path.
• Four teams in parallel in steel works. Three
different suppliers of steel. Foundations were
completed 1 week ahead of schedule.
CAPE VERDE PROJECT
(CAPE VERDE ISLANDSAFRICA)
30 MW. VESTAS 0.85 MW
2011-2012
26 | Construction of WWP in New & Emerging Markets|
CAPE VERDE
4 WINDFARMS IN 4 DIFFERENT ISLANDS
SANTIAGO:
SAL:
SAN VICENTE:
BOAVISTA:
27 | Construction of WWP in New & Emerging Markets|
11 WTG.
9 WTG.
7 WTG.
5 WTG.
CAPE VERDE
CHALLENGES
• WORK WITH LOCAL CONTRACTORS: No past experience in renewables.
• LOGISTICS. SEA AND GROUND SHIPPINGS TO 4 ISLANDS: Materials arrived from Portugal &
Italy.
• ELECTRICAL GRID. In poor condition suffering continuous blackouts. Engineering was focused also to
provide stability to the grid.
• 4 ISLANDS  PHYSICAL SEPARATION OF THE SITES.
• SOCIAL MANAGEMENT. Project was focused in a social training process, involving local community,
sharing knowledge about renewable energy benefits, and creating a change in their mindset. Currently
wind farms provide 25% of country´s energy, reducing dependence on fossil fuels imports.
28 | Construction of WWP in New & Emerging Markets|
CAPE VERDE
SOLUTIONS
• COMPLETE TURN-KEY PROJECT. GES managed all activities, including detailed engineering
(Electrical & Civil), Sea & Ground shipping of all components (towers, blades, foundation rings,
transformers, switchgears, MV cables etc.), Construction, WTG Erection and start-up.
• LOCAL ADAPTATION: Portuguese-speaking staff recruitment. Shaped Multidisciplinary staff for
mixing local knowledge with construction skills from GES staff.
• DIFFERENT STAFF DEPLOYMENT AT EACH ISLAND. For completing works on schedule four
different teams were deployed in each island and specialists were circulated according to
progress of works.
• NIGHT WORKS: Procedures and H&S rules were created to allow turbine erection when wind
speed was much lower.
• UTILITY RELATIONSHIP: Through local government, a network was put in place composed by
utility representatives, local engineering firms and GES for setting up electrical requirements for
connecting wind farms to the grid, and enhancing grid quality, making it more stable and avoiding
blackouts.
29 | Construction of WWP in New & Emerging Markets|
CAPE VERDE
MAIN ACCOMPLISHMENTS
• THE
PROJECT
ACHIEVED
ALL
DEADLINES WITH NO ACCIDENTS
• This wind farm produces 100 GWh a
year and brings benefits to 95% of
the population across four islands. It
has been considered a key project for
Africa's future energy needs, securing
economic growth and reducing
poverty.
• CAPE VERDE project was named in
2011 as “BEST RENEWABLE PROJECT
IN AFRICA”, awarded at the Africa
Energy Awards held in Johannesburg.
30 | Construction of WWP in New & Emerging Markets|
CAPE VERDE PROJECT
31 | Construction of WWP in New & Emerging Markets|
SALBATICA (ROMANIA)
140 MW. GAMESA G90 - 2 MW
2010-2011
32 | Construction of WWP in New & Emerging Markets|
SALBATICA
CHALLENGES
• SPECIAL PROJECT. First big development by Enel Green Power in Romania after their 34MW of Dealul
Pietros in 2009-2010, also with GES Romania. It is still one of the largest wind farms in Romania.
• LOCAL INVOLVEMENT. The Client and Regional Adminsitration requested a clear dedication with local
resources in order to promote and develop the area as much as possible. Also, enviromental issues,
since Project was in Natura 2000 area (close to Danube Delta), required a strong local support.
• TRUST BUILDING. It continued the long-term relationship of GES with key partners and clients.This
project came as an extension of the previous one and it finished with an agreement for a third
project with EGP in Romania.
• TECHNICAL DIFFICULTIES. Big dimension foundations (700m3) over deep piles (up to 30 meters),
mixed with shallow foundation over extremely hard basalt. Distances between turbines were quite big
due to orography. Beautiful nature that had to be preserved at any price.
• FULL SCOPE PROJECT. GES was involved in both BOP and Assembly
33 | Construction of WWP in New & Emerging Markets|
SALBATICA
SOLUTIONS APPLIED AND RESULTS
• LOCAL INVOLVEMENT. Companies from the area (Tulcea) were open to enter the project and after
some adaptation period, they were the best partners of GES due to their knowlwdge of local solutions
• TIGHT PLANNING. The project was split in 3 phases of 30, 40 and 70 MW reaching the final 140MW.
For each phase, GES managed to reduce the expected execution term up to 8 weeks. This quick
execution helped both Enel as final clients and also GES by making easier the Assembly and
Commisionning task.
• FOUNDATION WORKS. The most restrictive task, since winter period does not allow working in
concrete works. Up to 3 drilling teams on site to accomplish pile execution. High rhythm for foundation
casting, managing up to 4 foundations per week.
• 2 MAIN CRANES + 1 PREASSEMBLY TEAM. In order to respect the short erection plannings & staff.
• SALBATICA WAS FULLY CONNECTED WITH SOME MONTHS IN ADVANCE. This project helped GES to
prove our experience in stress situations and increased our reputation in the region. GES has
constructed more than 450MW in BOP in Romania.
• ENVIROMENTAL AND LOCAL RESPECT. The Delta of the Danube area and their people were respected,
and the new technology gained their respect too.
34 | Construction of WWP in New & Emerging Markets|
SALBATICA
MAIN ACCOMPLISHMENTS
Up to 3 drilling devices for deep piling.
Scope: Full BOP + Assembly
35 | Construction of WWP in New & Emerging Markets|
Fighting with extreme weather conditions.
Big dimension foundations in very short time
SO …
36 | Construction of WWP in New & Emerging Markets|
WHY GES?
YOUR PARTNER …
ALL OVER THE WORLD
ON THE MOST CHALLENGING PROJECTS
THROUGH THE WHOLE VALUE CHAIN
THROUGH THE LIFETIME OF THE PLANT
37 | Construction of WWP in New & Emerging Markets|
THANK YOU
Aydin Altunordu – aaltunordu@services-ges.com
Jose Luis Sevillano – jlsevillano@services-ges.com
38 | Construction of WWP in New & Emerging Markets|