Professional Documents
Culture Documents
Authors:
Adriana Mascolo
Enrico Arlango
Sarah-Jaqueline Kuhn
Elena-Laura Weber
Ana Maciel
Laura Villageois
Nikolaos Balotis
Amir Roshangah
Summary
Executive summary................................................................................................................................... 4
1.Genereal Information ............................................................................................................................. 5
1.1. Details of the petitioner.............................................................................................................. 5
1.2. Details of the owner ................................................................................................................... 6
1.3. Details of the construction work................................................................................................ 6
2. Project Overview ................................................................................................................................... 6
2.1 Project summary and description .................................................................................................. 6
2.2. Project Scope ................................................................................................................................. 7
2.2.1. Scope Definition and business objectives ............................................................................ 7
2.2.2. Boundaries .............................................................................................................................. 8
2.3 Project Approach ............................................................................................................................ 8
2.4 Work Breakdown Structure ............................................................................................................ 9
2.5. Milestones .....................................................................................................................................11
2.6 Estimated Schedule .......................................................................................................................12
3. Project Organization.........................................................................................................................13
3.1. Company description...................................................................................................................13
3.2. Project team structure.................................................................................................................14
3.3. Roles and Responsibilities............................................................................................................15
3.4. Personal Resources......................................................................................................................15
3.5. Project facilities and resources ....................................................................................................17
3.6. Promoter, stakeholders and board ..............................................................................................17
3.7. Sponsor/teacher ..........................................................................................................................18
3.8 Project controls .................................................................................................................................19
4.Product description .................................................................................................................................20
4.1 PDS Product Data Specification .........................................................................................................20
4.1.1 Economic and financial level .......................................................................................................20
4.1.2 In relation to the market ............................................................................................................21
4.1.3 In relation to the design..............................................................................................................21
4.1.4 In connection with the engineering and manufacturing ..............................................................22
4.1.5 In terms of organization and management .................................................................................23
4.2. Overview of product process or facility to be developed, main characteristics..................................24
4.3. Location map and environmental analysis .......................................................................................25
Windpark Distribution .........................................................................................................................28
4.4. Parts/subsystems that make up the installation and justify their necessities ....................................29
4.4.1. Turbines ....................................................................................................................................29
4.4.2. Cable .........................................................................................................................................30
4.4.3. Foundation ................................................................................................................................30
4.4.4. Transformers .............................................................................................................................31
4.5.Building up Process ...........................................................................................................................32
4.5.1. Detailed Process ........................................................................................................................33
4.6. Commissioning and Testing Stage.....................................................................................................34
4.7. General operation of the facility .......................................................................................................35
4.7.1. Control Strategies ......................................................................................................................35
4.8. Maintenenance Plan ........................................................................................................................36
4.8.1. Detailed maintenance activities .................................................................................................37
4.9. Catalogue of components.................................................................................................................37
5. The alternative approach ....................................................................................................................42
6. Quality tools ...........................................................................................................................................44
6.1. FMEA ...............................................................................................................................................44
6.2. QFD ..................................................................................................................................................45
6.3. FISHBONE.........................................................................................................................................45
6.4. SWOT ...............................................................................................................................................46
7. Costs .......................................................................................................................................................46
7.1. Cost estimation ................................................................................................................................46
7.2 Cost Budgeting ..................................................................................................................................47
7.3 Revenues estimation .........................................................................................................................48
8. Risks .......................................................................................................................................................50
8.1. Risk identification .............................................................................................................................50
8.2 CONTIGENCY PLAN ............................................................................................................................51
8.3 Opportunities ....................................................................................................................................52
9. References ..............................................................................................................................................53
Executive summary
The scope of the project includes the design, procurement, construction and commissioning of a
Wind Farm in Catalunya region of Spain for Som Energia. The project is planned to begin on 23rd
of October 2019 and the installation will be operative in 16 months. The wind farm will provide
sustainable energy for approximately 6,000 homes and it’s lifecycle and insurance is for 25 years.
Som Energia is a power production company which is particularly active in the Renewable Energy
field and starting good collaboration with this company could result in a good future prospect for
Futura Energy. The strategic goal of this project is to develop a key partnership with Som Energia
and gain notoriety and shares of the Spanish Renewable Energy Market. The scope of the project
is to get access to the market.
The forecasted budget is of 30 million euros for a total duration of 16 months, in this amount is
included the compensation for the company. Futura Energy will not have to invest in this project, but
just have to use the budget invested by Som Energia in a competitive way, in order to provide a good
product but also to gain the right compensation for the work done. The service includes the
mechanical, electrical and civil design of the wind farm, procurement of the construction material,
civil works to construct the site, the erection of the wind turbines and construction of the facilities to
manage the windfarm and its connection with grid. The project delivery method is Design-Bid-Build.
Once the construction is completed, the wind farm would be handed over to Som Energia who is the
customer. The project also includes the training of the Som Energia Technical staff for the proper
operation of the wind farm.
With regard to the regulations the equipment of the park must respect the environmental laws and
must be placed in a site that is far from houses in order to not be dangerous for local people. As for
the new wind farms, there are two aspects of EU directives to be kept in particular consideration
depending on the site of the plant:
1) at the Natura 2000 (Nature Protection Areas in EU) sites and surrounding areas: each
new wind farm which may have effects on one or more Natura 2000 sites must be subject
to an evaluation o gradual impact and, if necessary, provide for the application of the
necessary guarantees procedural protection of the types of species and habitats of
Community interest
2) anywhere in the EU: the two directives also stipulate that Member States protect species
of community interest in their natural area of distribution throughout the EU (Article 5 of
the Birds Directive and Article 12 of the Habitats Directive referred to above). Therefore,
each new wind farm must also take into consideration the possible impacts on species of
Community interest (covered by the two directives).
The project will be carried out in accordance with the previous guidelines, otherwise there is a risk
that it will not be completed, due to a failure in obtaining the necessary permits.
1.Genereal Information
The project DRAFT is a document that includes every single work part that is needed to work out a
project. It should be an informative document for stakeholders and investors. In the following DRAFT
document, you will get a small insight to our project. After you have read this DRAFT you will know
all the necessary technical, economic and ecologic aspects that need to be considered for our
Project, the Futura Energy wind farm.
The draft is divided in the following topics:
Executive summary: sums up the whole project content
General information: includes a very short introduction with the main information you will get
reading the draft, the details of the petitioner, the owner and the construction work.
Project overview: describes the scope and the reason for this project and the work that needs
to be done
Project organization: describes Futura Energy as a company, the team and team structure
with their rules and responsibilities, the personal and facility resources and project control
possibilities
Product description: overview of the product process or facility to be developed, main
characteristics
The alternative approach: discussion and finding an alternative or the best approach
Quality tools: Helpful quality management tool for work out the project
Costs: cost estimation, budgeting and revenues
Risks: deals with all the risks that can affect our project and how to avoid them
Phone: 900.103.605
Before we can start with the construction work there need to be done legal works, talks to the
governments, fulfilling all legal rules and finally finding a place to build up our wind farm.
The preliminary work and renting of the place is done by Som Energia after we had done a lot of
wind and market analysis and have suggested them a few possible places. The chosen location
must also take into account that less concurrence is possible, so that Som Energia stays a large part
of the market. Basing on this considerations the best chose of the location was in the mountain
region of Catalunya. There are also possible locations in other countrys, but Som Energia preferred
to expand first in the Spanish region and then in the next five years expand in other countrys in the
EU.
2. Project Overview
3. Training client Personnel before handover 3. Maintenance of the facilities after handover
5. Choose the best turbines after wind analysis and 5. Design of turbines and R&D studies to improve
buy them from suppliers. their quality.
4.1.Delivery of
1.3.Scope 2.2.Technical 3.1.Internal 3.2.External
1.1.Initiation 1.2.Scheduling 2.1.Planning 2.3.Budgeting 2.4.Closing Final
Management Design Changes Control Control
Documentation
4.3.Milestone :
1.2.2.Revise 1.3.2.Revise 2.1.2.Scope 2.2.2.Wind 3.1.2.Project 3.2.2.Milestone :
1.1.2.Develop 2.3.2.Accounting 2.4.2.Revise Final Project Sponsor
Gantt Scope Statement Definition Energy Potential Charter Changes Gantt Sponsor
Project Charter Draft Approval
Control Feedback
3.1.10.Scope
2.2.11.Equipmen Statement Control
t Transportation
and Procedure
3.1.11.Scope
2.2.12.Turbines Statement
Installation Changes Control
Procedure
3.1.12.Milestone :
2.2.13.Turbines Scope Statement
Foundations Feedback
2.2.14.Grid
Modification
Review
2.2.15.Civil
Implementation
Review
2.2.16.Equipmen
t Transportation
Review
2.2.17.Turbines
Installation
Review
In the appendix the tabular view of Work Breakdown Structure with the WBS dictionary is attached.
2.5. Milestones
Project proposal Defines the issue to be developed through the project. 25/09/2019
Project charter The purpose of the charter is to obtain formal approval on 16/10/2019
the general parameters and structure of the proposed
project, including objectives, milestones, organization,
governance structure, and stakeholders.
Project scope Scope statement outlines the project’s deliverables and 06/11/2019
statement identifies the constraints, assumptions, key success factors
and preliminary evaluation of the wind farm location. The
used turbines and transformers will be chosen as well.
Project draft The draft will allow a detailed overview of each part and 13/11/2019
phase of the project.
Project Gantt The purpose of a Gantt chart is to expose the time spent 20/11/2019
expected for different tasks or activities during a given
overall time.
3. Project Organization
3.1. Company description
Futura Energys goal is to contribute to a better environment, to use raw materials more sustainable
and to reach the minds of the people to be more aware of the importance to handle the earth and
their environment in a good way.
Futura Energy is a young EPC company in the renewable energy sector. EPC stands for energy-
procurement-construction, refering to the turnkey activities by which the company works out the
entire range of design, material, procurement and construction of a project. Futura Energy builds
wind parks, from designing to commissioning and then sells them to operator companies. The
optimal, innovative design and efficient implementation of the wind park in the environment helps to
increase its productivity. At this point the expertise of an EPC company like Futura Energy is useful.
The key roles of an EPC company for example of Futura energy are:
- The realistic planning and timing of the project
- Efficient and economic design of the wind park
- Procure the source material and equipment globally from proven manufacturers, preferably
from the area
- Managing logistics from delivering to storing from the material and equipment
- Be aware of deadlines
- Optimize the cost of the project, through design, material, equipment, personal resources, …
- Using industry standards and following legal rules
Futura Energy has a strong desire to expand its grasp in the renewable energy sector. For this
reason, it is specialized in local and international renewable energy projects.
Its aim is to produce and use more green energy to use less fossil energy and to save the last natural
resources of the earth. As said before Futura Energy does not run any renewable energy plants, but
design, built and install them before selling and handing them out to other companies for use.
The renewable energy sector is a more and more growing sector with a big potential of development
in the future and will secure enough work, projects and jobs for people, because one day there will
be no natural resources left. It is not a new sector and also not an old one and Futura Energy is a
very young company but with an international team from each parts of the world and with a lot of
different knowledges and strengths that can be developed and Futura Energy will grow, so the
competition is manageable.
In order to achieve the project goals Futura Energy works with a lot of contracted partners, for
example a building company, that sets up the wind turbines under our supervision.
Futura Energy is an LLC, limited liability corporation. All eight team members are also the owners of
Futura Energy in equal shares, but not personally liable for the companys depts or liabilities. An LLC
is a more formal partnership arrangement which requires articles of organization to be filed with the
state. An LLC is much easier to set up than a corporation and provides more flexibility and protection.
LLCs don't pay taxes themselves. Instead, profits and losses are listed on the personal tax returns
of the owner(s). If fraud is detected or if a company hasn't met legal and reporting requirements,
creditors may be able to go after the members. Am LLC is the most popular form of a corporate
structure and fits the best with our new and small start-up company.
Kitchen 1
- fridge, microwave, oven, drinks automat
- SAP
- simulation programs
- Open Office package
Software 5
- CAD
- Photoshop
- enough licences for each system
- domaine with emails and website
3.7. Sponsor/teacher
At this point, we would like to thank all Futura Energy employees, our contracted cooperation
companies, and especially Som Energia, our sponsor and project officer.
Without you, the project would not have been feasible in this way. Above all, the sponsored budget
from Som Energia for the project conversion was a great help. Som Energia and our cooperation
partners have always been available to assist with any queries we may have had, and that's how
this great project worked out. We hope in the future for another, great cooperation with you all.
This project will guarantee Futura Energy a big financial profit along with an access to the Spanish
renewable energy marketplace. Furthermore, this project will increase Futura Energy’s dominion
over the renewable energy sector and will be a keystone for its future financial success.
3.8 Project controls
Typical project controls are steering committee meetings, monthly status reports, risk management
assessment and mitigation planning and monitoring, issue management, changemanagement, and
communication management. They are itemized in the following points below.
Numerous meetings are held on a weekly basis and involve the high-level decision-making
authorities of the project, in order to check that it is being carried out correctly and that it is on time.
Aside from the general guidance of the project and instructing the project/program manager, steering
committees are entrusted with the decisions that ultimately determine how the project will look upon
conclusion. Some common tasks and decisions steering committees deal with include:
● Monitoring progress
The progress of the project will be monitored monthly, summarizing achievements and delays
occurring during the previous month. Pinpointing the causes for them and looking to find short- and
long-term solutions and improvements.
3. Risk Management
The project’s risks are closely monitored to ensure its safety, and if needed, mitigation actions can
be applied accordingly.
The strategy is to allocate the contingency funds to the relative WBE, when the risk is “closed” so
the uncertainty disappear it can be used because the risk occurred and it impacted the project, or
release to margin because the risk has not occurred.
4. Issue Management
Any issues regarding the project will be thoroughly recorded in an issue database. Specifying issue
details and actions taken, as well as people involved. Its current status and update reports will be
closely monitored by the team. All Issues will be informed in the project status report.
Special meetings for issue monitoring will be held once a month, where progress of the solutions will
be analyzed and discussed, seeking improvement and effectiveness.
5. Change Management
All change requests will be submitted and reviewed accordingly by the team and project manager.
Considering scope, costs, and alternatives. All change requests will need their appropriate approval.
Any change made in the Project Management Plan will be recorded in a change database. Further
tracking of the effects of these changes will also be recorded.
6. Communication Management
In order to ensure proper and effective communication, the following actions need to be taken:
The project team have weekly update meetings to review the work done and determine priorities. In
these meetings the project status is presented weekly, including progress, issues, improvements
and changes made during the week. Urgent matters are highlighted and discussed with the
appropriate team members.
The project status is presented to the project sponsors once every two weeks, highlighting completed
tasks and important decisions made during this time frame. In that moment the project manager
provides to the project sponsor reports about meeting minutes, developments done in the two weeks
before, problems and possible solutions about the project status.
All important documents and data that all people involved should have access too, will be uploaded
and daily updated in a private project web site.
4.Product description
4.1 PDS Product Data Specification
4.1.1 Economic and financial level
Number of units produced:
We will first produce one windpark with 20-30 turbines and then grow and make the windpark
building universal for other locations. This project will guarantee us to step into the market
and get future projects.
Site analysis
delivery design
training of
construction
personnel
4.1.2 In relation to the market
Product type, general characteristics (functional and level of performance):
The product is a windpark consisting of 20-30 turbines that produce green energy in using
the wind. 500KW power procudtion for one windwheel, so in total 10000KW production of
energy.
Price level:
The pricelevel is related to the windwheel industry in the middle range. One windwheel will
cost around one to three million euros.
Positioning:
We will place the wind farm in Girona a part of Catalunya region of Spain. We had a few more
locations, also outside of Spain that have been possible to install a wind farm, but Som
Energia preferred a location in Spain and decided after market and wind analysis on this one.
Target:
Build a windpark that generates green energy for the surrounded areas and providing the
costumer a whole functional windpark, national energy supply company
Importance of packaging:
Windwheels are not packaged, they were delivered to the location they are needed with a
heavy transport car, so there is no packaging needed.
Maximum dimensions:
The tower height will be around 40-65m the rotor diameter around 40m and on top there will
be installized a engine house with the generator.
Aesthetic recommendations:
We try to choose the best wind wheel depending on space, performance, power and size. It
is possible to color the bottom of the windwheel relating to the environment, but not the whole
windwheel, because e.g. planes still needs to see them.
Ergonomic considerations:
We don’t have ergonomic considerations for this product, because we use big machines for
transport and building.
Areas of use:
The using area is to transform free energy from the wind to electric energy. So producing
green energy, without using finite resources.
Adaptation and integration of the product with the environment or with other devices:
The best areas for windparks are the areas with a lot of wind, but you have to ensure that
you don’t disturb people living near and the environment with all its organisms. Furthermore
you need enough space, so that every windwheel has its own wind sluice. And you need
electrical lines for transporting the generated current and connect it to the grid.
The wind farm maximum energy production is 10 MW made of 20 wind turbines with rated power of
500 kW each. The emplacement is in the Alt Empordà, a zone well known for its high wind peaks.
The basic idea of the plant is as shown in picture 1.
With a special program and the data from the wind analysis, it would calculate an approximate value
of how much energy we produce with one wind turbine or with the 20 wind turbines.
1 wind turbine produces 570 MWh per year. This means that with the complete wind farm we produce
about 11400 MWh of electricity per year.
In order to have a successful project one of the most important criteria is the location. Since wind
farms have a notable visual, acoustic and biological impact, an analysis is been done and shown
below.
The most important criteria is to have enough wind to power the turbines and make them work in its
maximum working ratio. The Empordà, north east of Catalunya, is well known for the high wind. In
the map below it’s shown the average wind speed of the community.
As we can see the Empordà zone is one of the windiest but the place we need has to have also the
minimum ecological impact. The zone is surrounded by small rivers and has a lot of bird migration
so this have to be taken in account and build it far from them.
Map 2: Protected areas from Catalunya(Data from SENP).
We can see that the highest windy zone is the one that is protected. Having in account these and
the analysis of the ICO(Catalan Institute of Ornithology) of the migration of 5 different spices of birds
and that the period where the birds migrate are the mid-seasons(Spring and Autumn). We assume
that those maps are valid to make an approach of the location.
Another important factor is the accessibility to the grid. The closest the installation, the cheapest the
cost.
Map 4: National spanish grid of electricity. Taken from Red Eléctrica de España.
To reduce costs is very important to be close to a road so we can build the installation without making
new roads. Putting all this information in the map of Alt Empordà we get that the place in the purple
circle is the place where the far should be located.
In this map we can see the main villages and roads. The green zone is protected because of
biological resources and we don’t want to harm the environment. and the blue zone has too low wind
power. The blue and white line is the electrical grid.
The purple area is chosen as the optimal because it accomplishes with the exposed criteria, it’s far
from the most touristic zone(cost) and is closest to the high wind area.
Taking a deeper look in the area between Capmany , Darnius and Biure and analyzing the population
we have chosen the Còrrec de la Jaça hill (42.347368, 2.863431) as it accomplishes the demands
and its not close to population.
Windpark Distribution
Now that we have the right emplacement for the park, we can proceed to distribute the windmills
along the place. There are some important points to keep in mind when setting up the wind park.
1. wind wheels have not to stand behind each other, otherwise a windwheel will take away the
wind from each other → producing less energy
2. Turbulence in wind farms is not uncommon, therefore the wind turbines should be installed
at a greater distance. the distance between 2 wind turbines should be as close as possible
to 3 times the length of a rotor blade.
Taking in account this and that the diameter of the turbine is approximately 40 m. We distributed
them like this and orientate them in the north north west direction.
Map 7: Distribution of the wind park. Image taken from Google Maps.
4.4. Parts/subsystems that make up the installation and justify their necessities
Several components are used for the Futura Energy wind farm system. The most important are the
turbines, the cables, the foundation and the transformers.
4.4.1. Turbines
Name: Enercon E-40/5.40
The wind turbine E-40/5.40 is produced by Enercon GmbH, a manufacturer from Germany.
This manufacturer has been in business since 1984. And is currently one of the best manufacturers
in the area of wind turbines.
The nominal power of the Enercon E-40/5.40 is 500kW.
At a wind speed of 2,5 m/s the wind turbine starts to work and produce energy. And the shutdown
speed is 25,0 m/s. This means that the rotors are attracted by a mechanical brake,
Because the forces caused by the wind are too strong and there is danger that the wind turbine will
break down.
The rotor diameter of Enercon E40/5.40 is 40,3m. The rotor area is 1275 m . In total the wind turbine
2
4.4.2. Cable
For the wind farm it used only high-quality cables, because the Futura Energy wind farm is designed
at least for 20 years of operation and it is not allowed to fail during this time.
Aluminum cables, copper cables and fiber optic cables are mainly used.
Aluminum cables & copper cables are used for wiring in the tower itself and for connecting to the
public power grid.
Fiber optic cables are also needed for the communication between the wind turbines and for the
monitoring.
4.4.3. Foundation
The foundation (basement) of a wind turbine is one of the most important points. The wind turbine is
exposed to high loads and forces, so the foundation must be particularly stable. For this purpose, a
steel grid is placed in the ground and poured with high-quality concrete.
In addition to that, concrete piles will used to support the entire foundation.
4.4.4. Transformers
In order to feed the electrical energy obtained from wind turbines into a power grid, this current must
be adapted to the grid frequency, phase position and voltage of the grid. The grid frequency in
Europe is 50Hz. To be able to feed into the grid, the wind power supplied must be synchronized
with this frequency. Technically, this is done in a transformer system.
The transformer is purchased from SIEMENS because they are known for their quality and
maintenance guarantee. Distribution transformers from Siemens guarantee high reliability, efficiency
and environmental performance. The modular system with its various design options ensures cost
efficiency and low maintenance.
Advantages:
High efficiency - low losses
Environmentally friendly
Mostly without maintenance
Low weight and high reliability
Worldwide availability
Customizable design
4.5.Building up Process
The entire process takes approximately one year from commencement of construction to commercial
operation. The construction operations process includes:
Mobilization
1. Construct lay-down
2. Officie trailer yard
Roadwork
1. Stake and build roads
2. Prepare sub-grade
3. Place aggregate
4. Install drainage structures
5. Compact and grade
6. Public road improvements, if necessary
Foundations
1. Excavation
2. Foundation installation: install rebar, pour concrete, foundation backfill
Turbine deliveries
Construct substation
Erection
1. Turbine erection and tower wiring
2. Building and setting rotor
Energize turbines
Site restoration
1. Reclaiming intersection expansions
2. Reseeding and gravel additions
Access Roads
Each wind turbine site begins with building construction access roads to connect the turbine sites.
After the wind turbines are installed, the construction access roads are converted to permanent
gravel access roads that are about 16 feet wide.
Turbine Foundations
The foundation for each wind turbine consists of a concrete spread footing that is buried 8-12 feet
underground, depending on soil conditions, and with a 4-6 foot tall cylindrical pedestal that is
exposed 6-10 inches above finish grade with a 10-15 foot gravel ring around it. Post construction,
farming and grazing activities can resume within 15 feet of the pedestal.
Turbine Construction
Wind turbines are composed of a tall tower, a 3-blade rotor, and a nacelle which houses all the gears,
generators and electrical conversion equipment. All the components are delivered and laid out on
temporary crane pad and assembly areas adjacent to the wind turbine foundations. Assembly begins
by bolting the tower base section to the foundation pedestal and then bolting the remaining tower
sections into position, followed by erecting the nacelle and the rotor using a very large tall crane.
Each turbine takes about 4 to 5 days to erect from offload to pre-assembly and effective staging of
components.
Electrical collection
An underground electrical collection system connects each wind turbine and carries the electricity
generated by each wind turbine to the to the project substation. In most cases, an overhead
transmission line is also installed connecting the project substation to the electrical grid
interconnection facility or point of interconnection (POI).
O&M Building
Construction of 5,000 square foot operations and maintenance building to house the onsite staff, the
equipment, and spare parts necessary for ongoing maintenance of the project.
Commercial Operation
Once all the wind turbines are fully operational and capable of producing power into the energy grid,
the construction phase is deemed complete and the project will be commissioned. After
commissioning is complete, the project will be handed over to the operations and maintenance crew.
As the grid, electrical works and turbines near the end of construction/installation the commissioning
and testing stage begins.
This stage involves specialist commissioning engineers and technicians who check, test and adjust
the equipment until it is ready to operate safely and reliably.
At this stage, the wind farm (similar to any electrical generation facility) also carries out what is called
grid code compliance testing with the grid system operator. This ensures that the project meets the
rules the grid system operator sets out to maintain the continued smooth, secure and reliable
operation of the electrical transmission and distribution systems.
At the end of commissioning, the wind turbines undergo an extended test phase, sometimes called
a reliability run before being finally handed over at the end of the commissioning stage. The project
manager and specialist engineers monitor the commissioning and testing to ensure everything
performs safely and reliably in accordance with the various contracts.
After this, during the Operational Stage the wind farm continues to undergo further grid code
compliance tests for a period of time until all the requirements of the system operators (have been
checked and certified.
Once the project is commissioned and tested it is handed over to the wind farm owner to begin life
as an operating wind farm. The wind farm generates electricity which feeds into the electrical network
and provides clean renewable electricity to domestic and commercial electricity users.
The wind farm owner can either use in-house staff or specialist asset management consultants to
co- ordinate the wind farm operation. During the operations stage of a wind farm the operation and
reliability, maintenance, finance, ongoing compliance with permissions and permits, safety, security,
community relations and benefits, land-owner agreements etc. must be continually managed.
During operation the wind turbines and other key wind farm equipment are continually monitored
remotely via a computer system. Using this system, the wind farm owner, operations supervisor and
turbine maintenance contractor can monitor the wind farm production and performance to ensure it
is working efficiently. Where a fault occurs the computer system will identify it and inform the
supervisor who will send a maintenance crew to the site.
Typically, each wind turbine undergoes routine maintenance between two and four times a year
depending on the turbine type. Each routine maintenance can take number of days and involves at
least two service technicians. The maintenance technicians also carry out unscheduled maintenance
in response to faults or to replace components.
Civil works are routinely maintained as necessary, typically twice a year for routine maintenance.
The electrical infrastructure undergoes routine maintenance and testing at least once per year.
Monitoring of the civil and electrical works can also result in additional unscheduled maintenance.
The electricity produced by the wind farm is sold to customers and the income is used to pay back
the loans taken out at the pre-construction stage to construct the project, pay the maintenance
contractors, wind farm operators, utility charges, landowners rent, local authority rates, project
insurances etc.
In addition, windfarms can provide community benefit funds to local communities during their
operational stage. One modern wind turbine can contribute up to €250,000 to a local community over
its lifetime, making a significant positive contribution to the rural community adjacent to the wind
farm.
The angle of attack or pitch of the blade can be changed through a full ninety degrees as the wind
speed changes. In low wind speeds the pitch is set to capture as much wind as possible. As the wind
speed increases the pitch is continually changed to capture the maximum amount of power. Once
the power limit is reached the pitch is changed so as to begin spilling the energy from the rotor. The
pitch of the blades is changed by sophisticated hydraulic motors controlled by microprocessors. The
pitch angle of each blade is changed independently and because the whole blade is moved, even a
single blade is able to bring the rotor to a stop if there is a failure in the other two pitch controllers.
The pitch angle is reviewed very rapidly (and can be changed by large amounts (several degrees)
quite quickly. In this way it can respond to wind gusts and lulls and optimize the pitch of the blades
to optimize the energy capture of the rotor. The advantage of this regulation methods is that the
machine can also be detuned so as to reduce noise levels.
Condition Monitoring System (CMS) is a tool used in machine maintenance and is becoming a long
term service package for components. CMS provides information on what the condition of a
component is and can also predict an impending failure within the system.This includes: service and
maintenance; inspection; measuring and evaluating the machine conditions and estimating the
remaining service life. Machining process is extensively utilized within the turbine industry and
includes operations such as rotating, milling, drilling and grinding. Monitoring process involves
sensor measurements to determine the condition of the process. Analyzing measured signals,
detecting a process anomaly and detecting faults are necessary factors of the monitoring process.
SCADA
Supervisory Control And Data Acquisition (SCADA) is an application that collects data from a system
and send them to a central computer for monitoring and control usages. Remote measurements,
reporting data and monitoring information are known as telemetry.
The wind farm is designed to operate without intervention and are unattended for the majority of the
time. Each wind generator is able to operate completely independently of all other wind generators.
If conditions outside of the operating and safety parameters occur the generator will fail to a safe
condition. All safety and control systems have full redundancy to ensure safe operation.
Under normal circumstances, routine scheduled maintenance will be carried out approximately once
every six months. This scheduled maintenance of each wind generator will consist of oil changes,
brake pad replacement, bolt tightening, etc and takes approximately one day per generator. The
major component parts of the wind turbine generator are designed for the lifetime of the machine but
may occasionally require repair or replacement (this is not common).
The first few months of operation of the wind farm will require regular attendance at site by several
technicians to ensure that the wind generators ‘bed in’ properly and that all final construction and
commissioning tasks are attended to. On-going performance and reliability are continuously
monitored, including site inspections and if necessary a service team can carry out any unscheduled
maintenance.
4.8.1. Detailed maintenance activities
Enercon E-40/5.40
The wind turbine E-40/5.40 is a production of Enercon GmbH, a manufacturer from Germany. This
manufacturer has been in business since 1984.
The rated power of Enercon E-40/5.40 is 500,00 kW. At a wind speed of 2,5 m/s, the wind turbine
starts its work. the cut-out wind speed is 25,0 m/s.
The rotor diameter of the Enercon E-40/5.40 is 40,3 m. The rotor area amounts to 1.275,0 m². The
wind turbine is equipped with 3 rotor blades. The maximum rotor speed is 38,0 U/min.
In the generator, Enercon GmbH sets to synchronous. The manufacturer has used one generator
for the E-40/5.40. The maximum speed of the generator is 38,0 U/min. The voltage amounts to 440,0
V. At the mains frequency, the E-40/5.40 is at 50,0 Hz.
In the construction of the tower, the manufacturer uses Steel tube/ concrete. As corrosion protection
for the tower Enercon focuses on painted. Manufacturer of the tower is Pfleiderer / CAL.
Power
Rotor
Diameter 40,3 m
Number of blades 3
Tipspeed 80 m/s
Type Enercon 3
Manufacturer Enercon
Gear box
Stages 2
Ratio 90:1
Manufacturer -
Generator
Type Synchronous
Number 1.0
Voltage 440.0 V
Grid connection WR
Hersteller Enercon
Tower
Hub height 65 m
Shape Conical
Weight
Hub -
Rotor 2.7 t
Nacelle 26.5 t
Tower, mac 120.0 t
Miscellaneous
Installation -
Offshore No
Onshore Yes
Technical Features
Insulation Gas-insulated
Siemens high-voltage substations with air-insulated switchgear (AIS) are the cost-efficient choice for
rated voltages of up to 800 kV. They are renowned for highest reliability, economical operation, and
low maintenance requirements.
The Siemens experts always consider the electrical parameters as well as the environmental
conditions to which a substation is exposed. That’s why Siemens AIS substations meet even the
most demanding challenges and provide:
- an optimum solution when space restrictions and environmental circumstances are not an
issue;
- easy implementation of a wide range of standard applications;
- reliable switching for up to 800 kV, rated currents of up to 8,000 A, and short-circuit currents
of up to 80 kA.
Our company relies on Prysmian Group for the supply of cables and connectors that will be used
during the installation. Prysmian Group, created through the merge of Prysmian and Draka is the
world leader in cable manufacturer, energy solutions, telecom cables and systems and for any
information about the specifications of these components, please refer to the detailed catalogue on
the PG website.
5. The alternative approach
For the realization of the project there are two different solutions. The different solutions are listed
below.
The environmental conditions are the most significant ones for the decision which turbine to take for
the wind park.
In the region of Catalunya, there is an average wind speed of 5m/s. Compared with the rated wind
speed of both possible wind turbines, it is seen that the smaller turbine needs less wind speed to
reach the best power production. Compared to the Enercon E-700 E4 which reaches a power of
500kW at a wind speed of 7,5ms the Enercon E400-500 seems to be worse, but compared to the
total power the turbine with the 70m rotor diameter would be way more overdesigned than the little
turbine.
Even the costs per turbine are a significant factor when deciding for a solution. For the 20 turbines
solution the price would be 20.000.000€. Compared to the solution with the big turbines the price is
less. Therefore, the solution with the big turbines would blast the project budget.
In the final the space needed for the wind park needs to be compared. For the E400-500 turbine we
would need a space of 3ha. That’s a third more space needed than for the huge turbines. In addition,
it is needed to compare the environmental change due to the wind wheels. The smaller wind turbines
are less noisy and aren’t that huge. Therefore, they don’t destroy the environment in such a huge
way than the huge turbines.
In final Futura Energy decided for the Enercon E400-500 to have less complications with residents
close to the wind park and to have less overdesign, because most wind turbines produced nowadays
are getting huger to a production of almost 6 but in Catalunya the average wind speed isn’t suitable
for the huge turbines. Even the price decision is a relevant factor for deciding for the E400-500.
6. Quality tools
6.1. FMEA
An FMEA, Failure Mode and Effects Analysis is a tool to identify and quantify project risks and to
think how you can avoid them or which action you need to take to erase the risks or to improve the
RPN number. We analysed the windhweel in the following FMEA.
6.2. QFD
The Quality function deployment tool, is a comprehensive technique that is used to help build in
customer demands into a product during the design stage. We did the Quality Function Deployment
for different aspects like design, environment, function.
6.3. FISHBONE
A fishbone diagram is also called a cause and effect diagram or Ishikawa diagram. It is a visualization
tool for categorizing the potential causes of a problem in order to identify its main causes. The
following one display the main failure causes and effects on the wind farm and the windwheels.
6.4. SWOT
A SWOT Analysis has been conducted to achieve a better insight of the project, it is presented
below.
7. Costs
7.1. Cost estimation
A cost estimate is a summation of all the costs involved in successfully finishing a project, from
inception to completion. Cost estimates are typically revised and updated as the project’s scope
becomes more precise and project risks are realized, as the Project Management Body of
Knowledge (PMBOK) notes, cost estimating is an iterative process.
The forecasted budget invested by Som Energia is 30 million euros. Thus, Futura Energy will not
have to invest in order to complete the project, but only to use it in a competitive way. These project
costs can be categorized in many ways and levels of detail, in this case we divided the overall cost
in three main parts:
1. Financing cost
2. Material cost
3. Crew cost
The project costs start with financing cost including expenditures on land purchase, permits and
insurance which are not high and take only 10% of overall cost. In this project, material costs have
the biggest share with more than 85%, in which the turbines are the most expensive item by 69% of
overall project cost. The crew cost includes the salary for engineers, assistants and managers and
wage for workers which represent only 3% spreads along the project life cycle.
The estimated costs of the project are the ones shown in the table below.
Item Estimated cost (€)
Financing cost Obtain land rights 1,000,000
10% Permits 4,000
Insurances 2,000,000
Material cost Turbines 20,000,000
87% Foundation 2,700,000
Construction material 1,400,000
Equipment and facilities 700,000
Transportation 650,000
Crew cost Salaries 750,000
3%
The shares of the project costs are representedin the chart below.
Monthly cost
14.000.000
12.000.000
10.000.000
8.000.000
6.000.000
4.000.000
2.000.000
0
01/03/2020
01/04/2020
01/05/2020
01/10/2019
01/11/2019
01/12/2019
01/01/2020
01/02/2020
01/06/2020
01/07/2020
01/08/2020
01/09/2020
01/10/2020
01/11/2020
01/12/2020
01/01/2021
Moreover, a cumulated cost curve can be extrapolated from these data. It is a useful tool to compare
the real outflow with the predicted one. This curve gives information on the increasing of the project
irreversibility effect, when the costs raise it is more difficult to modify the project without spending big
amount of capital.
01/09/2020
01/12/2020
01/10/2019
01/12/2019
01/01/2020
01/02/2020
01/03/2020
01/04/2020
01/05/2020
01/06/2020
01/07/2020
01/08/2020
01/10/2020
01/11/2020
01/01/2021
01/02/2021
This analysis is the result of costs allocation on each milestones of the project, different dates of
payments and teams work periods are correlated to the development of respectively phases.
The big jumps in the S curve is due to the cost of turbines which are the most expensive part of the
budget.
Som Energia have invested 30 million euros for the installation of the wind farm by Futura Energy.
The price of electricity is sold about 0,2 €/kWh by Som Energia. The park is composed of 20 turbines
of 500 kW each. Thus, the revenues can be estimated.
In order to calculate the amount of money that the facility can potentially generate, is crucial to
consider the actual power generated from the wind, given its average distribution during the year.
The statistical evaluation of the average wind speed is performed through a software provided by
the company Enair, which is considered to be very reliable since it considers different and numerous
data from different databases and applies a different confidence interval for each of them.
Once the average wind speed has been obtained, the power actually extracted from the turbine is
calculated by means of another software which allows extremely precise results to be obtained as it
is specific for the Enercon turbine used.
Through the simulation, a power production of 0,57 GWh/ year is obtained for each turbine.
𝐾𝑤ℎ € €
570000 ∗ 0,2 = 114000
𝑦𝑒𝑎𝑟 𝐾𝑊ℎ 𝑦𝑒𝑎𝑟
This is the amount of money potentially generated for each wind turbine.
Considering the whole wind farm:
€
114000 ∗ 20 = 2280000 €
𝑦𝑒𝑎𝑟
Note that this is only a preliminary calculation which doesn’t take into account some important factors
such as the depreciation of the capital, the maintenance costs, the change in the price of electricity
etc. A more comprehensive approach will be carried out in the final version of the project.
8. Risks
8.1. Risk identification
Known project’s risks are closely monitored to ensure its safety, and if needed, mitigation actions
will be applied accordingly. As well, the team will be always on the lookout for any issues or risks
that might come up or that weren't originally considered.
Any issues regarding the project will be thoroughly recorded in an issue database. Specifying issue
details and actions taken, as well as people involved. Its current status and update reports will be
closely monitored by the team. All Issues will be informed in the project status report.
Special meetings for issue monitoring will be held once a month, where progress of the solutions will
be analyzed and discussed, seeking improvement and effectiveness.
Administrative risks
Listed below are the possible administrative risks the project has.
Probability Impact
No. Risk Description Planned Mitigation
(H/M/L) (H/M/L)
Probability Impact
No. Risk Description Planned Mitigation
(H/M/L) (H/M/L)
Our plan is to gather information in advance in order to avoid this problem at the beginning. The area
where we are planning our project is already exploited for a massive wind production, which means
there is a chance that we might not be able to get connected to the grid, this is why the risk level is
high and why we need to evaluate the all scenario at the very beginning.
2. Community acceptance.
Renewable energy is a technology that has a good acceptance from the clean power point of view,
but at the same time is considered a threaten for the environment (changing the migration of birds)
and for the common life (noisy sounds). This can be a problem for realisation of the project that is
why it important to Contact the local communities early, providing clear information about the
project's specification and impacts. Solve potential issues early.
3. Land leasing.
The land-owners of our site could ask too much money for the leasing and from an economic point
of view can make it impossible for the realization of the project. It’s important to identify and contact
the landowners as soon as possible, establish a representative to communicate and negotiate with
the land-owners.
The Spanish government is highly bureaucratic, therefore the permission process can lead to a delay
in the process creating problems since the beginning.
In this case can it’s fundamental to be informed in advance of every permission process, the political
considerations of the energy policy and be aware and conscious of any time request.
6. Security Breach.
During the construction phase there can be security breach that can cause loss of time and material.
It’s important to Increase security patrols and personnel, ask government for assistance, follow all
policies to further reduce risk.
8.3 Opportunities
In our project we have identified some risks that can be opportunities. They can be beneficial for the
company, our client, the local community and for the government.
In the tables below are reported the most important opportunities. Each of them can have a positive
impact from an economic point of view, and from a strategical point of view must be considered.
The opportunities, that a project can create, are the real value that it can have. They are an important
aspect to underline with all the stakeholders, considering mainly the sponsor of the project and the
client. Our company can be a leader in innovation mainly focusing on what it can create and make
better.
Each of them must be evaluated from the project management team that is in charge of consider all
the aspect of the project from different point of view.
9. References
Document Versio Date Author Location
Title n
and (link or path)
No. Organization