EPC SOLUTION FOR

2 X 50 MW WIND FARMS AT GHARO

Descon-Nordex Presentation
Lahore, Pakistan
 Agenda

• History
• Solution Proposed
• Contractual Structure
• Project Scope
• DOR
• BOP
• Value Proposition
 History

• Associated with the projects for the past 3 years.

• Descon Capabilities presented to IFC in 2007.
• LOIs issued in May 2009.
• Extensive engineering studies and design
evaluations conducted.
• Proposal and Term Sheet re-finalized in Oct 2009.
 Contract Structure
• Descon and Nordex have teamed up to act as a EPC
Contractor with Joint and Several Liability Exposure.
• Single EPC Contract with built in two years O & M
package as an integral Part
• Descon shall be the lead Contractor Party
• Each Contractor Party (Descon Onshore, Descon
Offshore,Nordex Onshore and Nordex Offshore) shall be
paid directly by the employer for the respective scope of
work.
 Wind Farm Project
Scope

• Civil, Supply of Tower, E&I Design,

• WTG Equipment Supply by Supply of BOP, Construction incl.
NORDEX installation/ Erection by DEL
 Major Project Scope
a. Engineering , Design ,Supply and Delivered at Site:
i. Towers with internals (both electrical & mechanical)
ii. Complete 22/132 KV AIS Substation as per WAPDA specs
iii. S 82 WTGs (Nacelles, Rotors, blades and invertors)
iv. Complete 22 KV overhead collection network including WTG transformers
& RMUs, cables etc.
v. Two years OEM recommended spares.
b. Civil Construction & Electromechanical Installation / Erection /
Commissioning
i. WTG Foundations and Crane Pads
ii. Access and internal wind farm roads
iii. Substation Buildings and Laydown area
iv. RMU & WTG Transformer Foundations
v. Fencings Around Individual WTG, Transformer ,RMU and substation
building.
c. Installation Erection and Commissioning.
d. O&M during the Warranty Period (2-years)
 Basic DOR
Responsibility
Work Scope
DEL Nordex Owner
Supply Wind Turbine Generator [WTG] with Converter, Nacelle, Hub & Blades, on X
CFR – Karachi basis
WTG Towers fabrication specifications and manufacturing supervision X X*
All Transportation in Pakistan X
Right of Way, Site acquisition, Insurance, Import permits, EIA, NTDC Grid X
Availability and Site security
Civil Infrastructure Design & Construction X X*
WTG Erection & Installation X X*
Electrical & Instrumentation System Supply, Design and Construction of collection X X*
network system
Pre-Commissioning & Commissioning Assistance X X*
WTG Commissioning & Substation Commissioning X X
Performance Warranty X X
WTG Availability & Power Curve Warranty , BOP Electrical System Warranty X X
O&M for 2 Years X X*

* Specifications /Supervision / Design Review

 BOP- Scope of Civil Works
1. Turbine Foundations - Deep foundations and shallow foundations
above improved ground.
2. Road Works – Upgrading of existing paved road as well as
construction of new access road and internal wind farm roads.
3. Crane Pads – For crane set-up close to each WTG location.
4. Laydown Yard.
5. Substation including Gantry – Foundations and civil super-
structure works.

6. Foundation for the collection system including poles, RMU and

WTG Transformer

7. Fencing
Site location
General Layout of Area.
Planned Access Roads
GP site
layout
Beacon Energy Ltd. Windfarm Site
Very loose and inaccessible site terrain
Water level fluctuation
 Parameters impacting Civil design
and Construction
1. Accessibility to site.
2. Geotechnical conditions at Site.
3. Tidal variations.
4. Wind speeds and loads.

5. Corrosive Environment.

The above concerns warrant the need of a thorough

engineering study of the project/s.
 Geotechnical data evaluated
DEL performed comprehensive geotechnical evaluation of the
geotechnical data provided by the Owner:

1. M/s Green Power (Pvt) Ltd. Geotechnical Report for

50MW Wind Power Plant near Gharo, Sindh by Soilmat
Engineers (December 2007).

2. Geotechnical Report for BEL’s Wind Turbine Project near

Gharo Distt: Thatta Sindh, Sindh by Soilmat Engineers
(May 2006).
 Geotechnical Characteristics
• Surficial conditions: very loose to loose; some vegetation.

• Subsurface profile: silty/clayey/sandy soils down to the entire depth of

investigation of 40m.

• SPT-N ranges between 1 to 32.

• C = 10 to 30 kN/m2; phi = 15-30 degrees.

• Groundwater table: 0.45m - 1.60m depth below EGL

Surficial soils with vegetation
Generally Flat site
Site submerged under water due to tidal
fluctuation
Loose soil on top with water
submergence
Geotechnical Drilling in progress
Geotechnical sampling
Seismic Characteristics
 Conclusion from Geotechnical
Investigation reports

• This subsurface is generally not considered competent to directly support the

anticipated loads from the WTGs as well as other structures of the wind
farm. Deep foundations or ground improvement needed on most locations.

• Additional Geotechnical data for BEL site will be needed.

• To finalize the foundation design Pile Load tests are essential.

• Allowable settlement = 25 mm (Shallow Spread footings)

• 50 mm (Shallow Mat/Raft)
 Topographic Survey
DEL evaluated the following available survey data:

1. Topographic Survey of Beacon Energy Land Parcel at Kuti

Kun New Island, Gharo by Techno-Consult International
(Feb. 2007).

2. Survey Report of Green Power and Beacon Energy Wind

Power Farms, Mir Pur Sakro - Sindh by Survey Engineers
(2009).

3. Technical Proposal for deepening and widening of Port

Qasim Navigational channel by ECIL and Loius Berger
Inc. (2009)
 Topographic Survey Findings

• The general site terrain described as flat with low changes in elevation.

• The spot elevations of various points across the site generally range
from 1.50m - 2.00m above the Survey of Pakistan (SOP) datum.
 Surface
profile at GP
site
 Surface
profile at BEL
site
 3D Surface
profile at BEL
site
 Tidal Study
DEL performed comprehensive evaluation of the following
available tidal data:

1. Tidal Analysis and Establishment of Reference Datum at

Kuti Kun New Island, Gharo, Sindh by Techno-Consult
International (October 2006).

2. Study of Drainage Lock Structure near GP Windfarm,

Gharo (July 2007).
Two Highs and Two Lows in
Tides daily
Installation of Tide Pole
Tide Height Monitoring
Conclusions from Topographic and
Tidal Studies
• Maximum expected tidal level = El. +2.50m wrt SOP
datum.
HWL = + 2.50 m (design value)

NSL = + 1.70 m (avg.)

MSL = ± 0.00 m (approx.

same as SOP)

LWL = - 1.30 m
 Load Data and Design Considerations

• Design Wind Velocity = 100 mph.

42
Recommended scheme for different civil
works
Finished levels (based on tidal evaluation)

• Tower foundation top of concrete = El. +3.80m wrt SOP datum i.e.
1.30m above highest tide level.

• Crane pad FGL = El. +3.50m wrt SOP datum.

• New Roads FGL = 0.30m above EGL.

• Laydown Yard FGL = El. +3.50m wrt SOP datum.

 Tower Foundation
Geotechnical Analysis:

• Shallow as well deep foundations were evaluated.

• Various sizes were checked through rigorous analysis to arrive upon the
technically most suitable.

• Analysis included:
• Bearing Capacity against Shear Failure.
• Estimate of foundation settlement.
• Pile Capacity Analysis (for compressive, tensile and lateral load
cases)
 Tower Foundation
Structural Analysis:

• Stresses in pile foundations and pile caps were evaluated.

• Total and differential settlement of piles for various load combinations

were calculated.

• Lateral deflections of piles for various load combinations were

calculated.
Settlement
Analysis
14m dia. pile
cap modeling
 14m dia.
Pile Cap
with 30m
deep piles
modeling
 Tower Foundation Recommendations

GP site:
• 15 Nos. towers supported on RCC pile foundations; pile dia. 900mm,
pile depth 30-35m; 15-18 piles below each pile cap; pile load test shall
be performed @ 1 test/5 WTGs as per ASTM.

• 18 Nos. towers supported on shallow foundations over improved

ground. Improvement thru shallow soil replacement by competent
structural fill and gravels/boulders.
• Dewatering is not envisaged in our proposed scheme. However, if
needed, properly designed shoring and dewatering systems would be
installed.

BEL Site:
• All towers supported on RCC pile foundations; pile dia. 900mm, pile
depth 30m; 15 piles below each pile cap.
Schematics of ground improvement below shallow foundations
Crane Pad
 Roads
1. Widening of existing road
• Existing road (9.5km long) along the canal will have to be widened to
accommodate the equipment/machinery.
• Widening to be done by borrowed Soil.
• Widening shall be done to maintain safe movement of project
equipment/vehicles (6m max.)
 Roads
2. Planned Access Road and Internal
Farm Roads
• These roads shall be built FIT TO PURPOSE.

• A detailed evaluation of various schemes was done as follows:

1.Permanent Asphalt Road upto El. +3.5m wrt SOP datum.
2.Granular road upto El. +3.5m wrt SOP datum.
3.Fit to Purpose granular road capable to only carry the
anticipated equipment/machinery to the WTG locations.

• Evaluation showed that option-3 is overall the most economical.

New Access Road and Internal Farm
Roads (…contd.)

• Parts of these roads will remain submerged under water. However, the
stone/gravel embankment would ensure the passage of large wheeled
vehicles such as tractors, excavators, rollers, trailers all the time.

• Periodic maintenance will be needed to make up the fill continuously

subsiding into ground
 Yard and Camp
• Yard to store the equipments and instruments such as tower, nacelle,
hub, blades etc.

• Yard shall be of 200m x 200m in plan.

• To be located at an area, where the NGL is higher than the average tidal
level.

• Constructed by filling upto El. +3.50m using locally available or

borrowed soil.
 Proposed
Laydown Yard
location
 BOP- Electrical scope of work

DEL scope is comprised of engineering, procurement and construction of

132kV Substation, Transformers and 24 kV Collection System as summarized
hereunder based upon WAPDA Standards, Draft Addendum to Grid Code and IEC
Recommendations

• Transformers

Two (2) Nos. of 22/132kV, 50 MVA ONAF Power Transformers

One(1) No. of 22/0.4 kV, 300 kVA ONAN Auxiliary Transformers

• 132KV substation
Five (5) bays of 132kV Switchgear 132kV, 40 KA for 1 sec comprising of two
(2) overhead line bays, two(2). transformer bays and one (1) bus section bay.

Main Proposal: Outdoor Conventional AIS

Alternate Proposal: Indoor GIS
• Protection, Controls and Metering

Protection for Overhead line, Transformers and Bus Section

Local controls with interface with substation SCADA, interlocking and back up
metering
• 24 KV MV Switchgear

Eleven (11) bays 24kV , 25 KA for 1 sec. Switchgear comprised of four bays for
collection system, two bays for power transformers, one for shunt compensation and
one spare outgoing bay complete with protection, local control, interlocking system
and interface with substation SCADA.
Main Proposal: Indoor Metal Clad
Alternate Proposal: Indoor GIS
• Auxiliary Supply System

400/240 V AC Auxiliary System including Distribution Board

One 300KVA Standby Diesel Generator
110V DC Auxiliary System including Distribution Board, 110V DC NiCd Battery and
duty and standby chargers
• 24 KV Collection System
The Collection System shall have 4 collection system strings
comprised of Generator step up (GSU) transformers 0.69/22 kV,1700 KVA ONAN,
Ring Main Units (RMUs) and 24kV overhead conductors complete with RCC poles.

Main Proposal: Overhead Aluminum Conductors

Alternate Proposal: Overhead Cables
Alternate Proposal: Off Shore underground Cables

• Telecommunication

Telecommunication equipment including line traps, HF co-axial cables, PLC and PSE
equipment, PABX, 48 V DC battery suitable for transmitting real time on line data of
the Wind Farm for the NPPC.
Five ISDN lines with PABX between control room and substation along with ISDN
line for SCADA server to connect with remote terminal.
• Substation SCADA
Substation Scada at wind farm has been included in DEL’s proposal.
However, RTU for 132kV Substation and modification including additional interface
card and extension of mimic in RPCC will be arranged by the project Company in co-
ordination with the Power Purchaser.
Basis and Assumptions for connectivity with
WAPDA
• The Owner’s Gird studies are based on Suzlon S82, new studies as per
Nordex N82 to be carried out by the Owner

• DEL has proposed distance and over current protections for 132 KV lines.

• The Owner will arrange WAPDA if any other protection will be required.

• DEL has proposed one set of Energy Meters, CTs and PTs for metering
purpose. The Owner shall arrange with Main Metering Panels from
WAPDA.

• DEL has proposed optimal location of 132kV substation for gantry point
interconnection between WAPDA grid and the Wind Farm. The Owner shall
arrange with WAPDA extension of existing WAPDA 132 kV Grid to each
Wind Farm.
Basis and Assumptions for connectivity with
WAPDA
• DEL and NDX has proposed reactive power compensation system to
comply with the draft Grid Code. The Owner to arrange with WAPDA for
their compliance as well to the draft Grid Code.

• DEL proposed completeness and functionality of mode of communication

medium for telecommunication and tele-metering. The Owner to arrange
with WAPDA to clarify the requirements on PLC Equipment.

• DEL’s has considered requirements for NTDC (WAPDA) data from GP

wind farm. The Owner to arrange with WAPDA to clarify the signal
requirements.
 Value Proposition
• World renowned German-Danish technology & quality

• One of the world most tested and tried machine design.

• The most suitable machine for the environmental conditions at Site.

• Single EPC contract with well defined split of scope between the Contractor
parties with a joint and several cover thus offering transparent control with
double protection to the Owner.

• Contractors committed to the local market, have signed the first EPC contract

• Long term strategy to serve the local market, Descon staff shall be trained on
the commissioning and O&M of the WTGs thus offering long term investment
protection to the Owner
 Value Proposition

• Competitive and bankable solution based on extensive working and elaborate

engineering efforts covering:
• Accessibility Requirements, Terrain And Geotechnical Characteristics

• Well defined and exhaustive scope of work

• Thorough Contractual Requirements

• Conceptual Design Of Civil Infrastructure, Foundations and Other Civil Related Scope

• Rigging Methodology Of WTGs

• Conceptual Electrical System Design and Local Utility Network Requirements knowledge

• Transportation Requirements