East Kerry North West Cork Project

Substation Construction Methodology

PE687-F0272-R272-006-000

ESBI Engineering Solutions Stephen Court, 18/21 St Stephens Green, Dublin 2, Ireland Telephone+353-1-703 8000 Fax+353-1-661 6600 www.esbi.ie

May 2012

File Reference:

PE687-F0272-R272-006-000

Client / Recipient:

EIRGRID

Project Title:

East Kerry North West Cork Project

Report Title:

Substation Construction Methodology

Report No.:

PE687-F0272-R272-006-000

Rev. No.:

Volume 1 of 1

Prepared by:

Eoin OMullane and Martina Kenny DATE: May 2012

APPROVED: TITLE: Overhead Line Design and Station Design

Latest Revision Summary:

COPYRIGHT ESB INTERNATIONAL LIMITED ALL RIGHTS RESERVED, NO PART OF THIS WORK MAY BE MODIFIED OR REPRODUCED OR COPIES IN ANY FORM OR BY ANY MEANS GRAPHIC, ELECTRONIC OR MECHANICAL, INCLUDING PHOTOCOPYING, RECORDING, TAPING OR INFORMATION AND RETRIEVAL SYSTEM, OR USED FOR ANY PURPOSE OTHER THAN ITS DESIGNATED PURPOSE, WITHOUT THE WRITTEN PERMISSION OF ESB INTERNATIONAL LIMITED.

BF-REP-001-002-003

PE687-F0272-R272-006-000

Change History of Report

Date New Rev Author Summary of Change

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Executive Summary
The purpose of this document is to outline and explain the construction techniques which will be used on the East Kerry North West Cork Project. This document is intended to be used as an aid to understand broad OHL (line cable interface tower) and substation construction methodologies. This document should be read in conjunction with the Environmental Report.

Contents
Executive Summary 1 2 Proposed Development Substation Construction 2.1 2.2 2.3 3 Preparing the Site Main Construction Electrical Installation Including Transformers i 2 3 3 3 4 5 5 6 6 7 7 7 8 8 8 8 9 9 11 13 14

Installation of Line Cable Interface Towers 3.1 3.1.1 3.1.2 3.2 3.2.1 3.2.2 Installation of Tower Foundations Construction Equipment Required Duration of Foundation Works Erection of Tower Body Construction Equipment Required Duration of Tower Erection Works

Monitoring and Mitigation Measures 4.1 4.2 4.3 4.4 4.5 Ecology Archaeology Soils and Water Construction Equipment Required Traffic Management

5 6 7

Waste Management Reinstatement of Land Summary

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Proposed Development
The proposed development in relation to the substation comprises three main elements: Construction of a substation of 1,989m2 gross floor space comprising a two storey Gas Insulated Switchgear (GIS) 220/11 kV substation, including: a 220 kV substation building of approx. 1,055m2 gross floor space and up to approx. 14.2m in height; construction of a two storey 110 kV substation building of approx. 934m2 gross floor space and up to approx. 12m in height; associated outdoor electrical equipment, including 2no. transformers in transformer bays located between the 220 and 110kV stations, 2no. lightning protection masts (approx. height 14m and 1 no. SCADA pole approx. height 20m); associated internal access road, car parking areas (10 no. parking spaces), boundary treatment including 2.6m high station perimeter fencing, 1.4m high boundary fencing and other site development works; all within a site of approximately 5 hectares;

Construction of an associated access road of approx. 600m in length and generally 6m in width, from the public road to the substation, and including a new vehicular entrance onto said public road;

Associated localised modifications to the existing Clashavoon Tarbert 220kV overhead transmission line (OHL) in order to loop this existing line into the proposed substation. These modifications consist of the removal of approx. 58m of the existing 220kV OHL and its replacement by 2 no. line cable interface towers (approx. height 21.5m)., and 2 x 220kV XLPE underground cables running inside the access road for approx. 500m connecting the proposed station with the line cable interface towers.

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Substation Construction
Prior to commencement of construction a detailed construction report will be prepared to detail all the processes and procedures which will be undertaken as part of the construction of the East Kerry North West Cork 220/110kV substation. Prior to commencement of work the contractor(s) will prepare method statements and work programmes that show more detailed phasing of work. The appointed contractor(s) will develop a series of detailed construction method statements for the construction of the substation. These method statements will detail how the contractor plans to implement the design and will take into account access to the substation site and any archaeological, hydrological and ecological issues relating thereto. It will also take into account site investigations, third party requirements, and mitigation measures outlined in the various sections of the environmental reports carried out prior to construction. The method statements produced by the contractor(s) will be agreed with the appropriate parties. EirGrid/ESBN will employ a team to monitor the construction phase of the project and ensure works are being carried out in accordance with the agreed method statement, safety procedures, pollution control, etc. It should be noted that this construction methodology is indicative and based on ESB Networks (ESBN) /EirGrids long experience in similar projects. Any issues specific to this project, for example unique planning conditions, will be incorporated fully into the appointed contractors scopes of work and careful supervision and management will be carried out to ensure full compliance. Below is an outline of the general construction activities associated with the substations. More specific details can be found in the Environmental reports.

The construction work will take place in three broad phases:

2.1

Preparing the Site

Site preparation is expected to take about 6 months and includes the following activities: (sequence to be agreed with ESB Networks/contractors and local authority prior to construction commencement) Site entrance. Site establishment. Public road modifications in accordance with the local authority's requirements. Construction of temporary site drainage works. Bulk earthworks, including site levelling and entrance road construction. Existing OHL enabling works.

2.2

Main Construction
The main civil works are expected to take approximately 8 months and includes the following: (sequence to be agreed with ESB Networks/contractors prior to construction commencement) 3
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110kV and 220kV GIS Buildings, including foundations works, structural steelwork erection, cladding and building finishing works. Construction of transformer compounds. Access road and bridge construction. Erection of line cable interface towers (x 2). Permanent foul and surface water drainage works. Paving. Fencing. Completion works.

2.3

Electrical Installation Including Transformers

The electrical installation is expected to take approximately 6 months (depending on contracts with ESB Networks) and includes the following: Delivery and installation of two 220/110kV transformers. These are unusually large and the deliveries will be managed in accordance with regulations governing the movement of large loads. Delivery and installation of all other HV equipment. Wiring and cabling of HV equipment and protection and control cabinets. Commissioning of all newly installed equipment.

For the duration of the construction phase of the substation there will be temporary welfare facilities installed. Normal working hours will be adhered to for the most part, however there may be some occasions where work will be undertaken outside of these hours. These occasions will be kept to a minimum. Any works or deliveries which are likely to have a significant impact in terms of noise or other disturbances will be avoided outside of normal working hours. The activities which is expected to have most impact during this construction is the traffic to and from the site. A traffic management plan will be implemented to mitigate against undue impacts.

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3.1

Installation of Line Cable Interface Towers

Installation of Tower Foundations
The tower sites will be checked for underground services such as cables, water pipes etc. If field drains are encountered these will be diverted and all diversions identified to the landowner. The tower will be set out and pegged prior to foundation excavation. This may require excavation of some existing ditches or drains to allow clear pegging of each individual leg footing for excavation. All such removals are restored upon completion of foundation works. It should be noted that pre-construction site investigations may show that ground conditions unsuitable to the standard foundations are present. In this case a modified, special foundation will be designed. A larger footing may be required in the case of weak soils, pile foundations may be required in the case of deep bog and reduced footing size foundations may be required in the case of rock being encountered at shallow depths. The tower stubs (lower part of tower leg) will be concreted into the ground. For each leg of the tower (4 in total) a foundation is excavated using a tracked excavator and the formation levels (depths) checked by the on site foreman. Each of the four corners of the tower will be separately anchored below ground in a block of concrete as per Figure 3.1 below. Any water in the excavation is pumped out prior to any concrete being poured into the foundation. Concrete trucks shall be brought as close as possible to the excavation to pour directly into the excavation. In the event of this not being possible concrete shall be transported in dumpers, in the event that the ground is very poor and wheel dumpers will not transport the concrete over the terrain, track dumpers may be used. In areas of poor ground or high water table it may be necessary to use sheetpiles supported by hydraulic frame(s) to prevent collapse of the sides of the excavation and also to prevent the excavation becoming too large. During any dewatering activities a standard water filtration system will be utilised to control the amount of sediment in surface water runoff. After this, the remaining part of the foundation, the concrete shear block or neck is formed using shuttering. During each pour the concrete shall be vibrated thoroughly using a vibrating poker. In the event that sheet piles have been used these are removed (pulled) at this stage. Care is taken not to damage the base members of the tower. The shear block formers are removed at this stage. The tower foundations are backfilled one leg at a time with the excavated material. The backfill is placed and compacted in layers. All dimensions are checked following the backfilling process. If the excavated material is deemed unsuitable for backfilling imported fill material may be used also compacted in layers. When the base construction crew leave site they shall ensure to remove all surplus materials from the site including all unused excavated fill. Once the tower base is completed and fully set (usually after seven days) it is ready to receive the tower body which is normally constructed in an area near he foundation site ready to be lifted and bolted into place.

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Figure 3.1: Photograph of a typical tower base with excavations.

3.1.1

Construction Equipment Required 4x4 vehicle Concrete vibrator Tractor and trailer Water pump Wheeled dumper or Track dumper (6 to 8 tons) Timber or other Shuttering boxes 360 tracked excavator (13 ton normally, 22 ton for rock breaker). Transit van Chains and other small tools Concrete delivered by supplier to closest convenient point (38 ton gross)

3.1.2

Duration of Foundation Works The average duration of foundation works is as follows: Line Cable Interface Tower Piled foundation Crew size 6-10 days 10 days 4 to 6 workers

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3.2

Erection of Tower Body

The steel for the remainder of the tower is delivered to the site by lorry and various sections of the tower, depending on weight and method of construction of the tower, are pre assembled on the ground beside the tower before lifting and bolting into position. The tower is normally lifted using a suitable all terrain (or Gin pole) crane.

3.2.1

Construction Equipment Required 4x4 vehicle Winch Tractor and trailer Crane Teleporter Transit van Chains an other small tools

3.2.2

Duration of Tower Erection Works The average duration of tower building works is as follows: Line Cable Interface Tower Crew size 4 days 7 workers

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Monitoring and Mitigation Measures

The following section provides the main forms of monitoring and mitigation measures which are proposed for the project. Reference to individual Environmental Reports should be made for specific details of mitigation measures proposed for individually identified sensitive sites.

4.1

Ecology
The following are the mitigation measures which will be carried out during construction: Specific mitigation measures as outlined in the Ecology report. Hedgerows: re-planting with broadleaves and component species. Watercourses: follow guidelines set by the former Regional Fisheries Board and approved by the Inland Fisheries Ireland (IFI). General: Following the recommendations in the environmental report, a site appropriate, Environmental Management Plan will be agreed before construction works.

4.2

Archaeology
The following are the mitigation measures which will be carried out during construction: Specific mitigation measures as outlined in the Cultural Heritage Environmental Report. Monitoring of site works in accordance with advice from the (Department of Arts, Heritage and the Gaeltacht (DAHG) is recommended. In accordance with the Code of Practice between EirGrid and the Minister of the Environment, Community and Local Government in relation to Archaeological Heritage (2009) a project archaeologist will be appointed to oversee the project.

4.3

Soils and Water

In accordance with the recommendations of the soil and geology and hydrology reports in the Environmental Report: Machinery during the construction phase will be managed to ensure that its access is limited to one entry and exit point. Minimise time for excavations being open as far as possible. During any dewatering activities a water filtration system will be utilised to control the amount of sediment in surface water runoff. Removal of vegetation will be limited to the area of excavation. The locally excavated material will be reinstated immediately following construction to allow recovery of any potential groundwater level change as quickly as possible. 8

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Aggregate will be imported rather than quarried on site. The contractor will be required to make provision for removal of any concrete washwaters, most likely by means of tankering off-site and no such washwaters will be discharged to groundwater. Soil stockpiles will remain undisturbed until re-use and reestablishment at the site. In order to reduce the risk of contamination arising as a result of spills or leakages, measures include, but are not limited to, the following: Storing fuels, chemicals, liquid and solid waste on impermeable surfaces. Undertaking refuelling of plant, equipment and vehicles on impermeable surfaces. Ensuring all tanks and drums are bunded in accordance with established best practice guidelines. Provision of spill kits at high risk sites.

Re-fuelling of construction equipment and the addition of hydraulic oil or lubricants to vehicles/ equipment will take place in designated bunded areas within the main construction compound. A drip tray will be used beneath the fill point during refuelling operations in order to contain any spillages that may occur. Spill-kits and hydrocarbon absorbent packs will be stored in the cabin of each vehicle and operators will be fully trained in the use of this equipment.

4.4

Construction Equipment Required

4x4 vehicle Wheeled dumper or Track dumper (6 to 8 tons) 360 tracked excavator (13 ton normally, 22 ton for rock breaker) Transit van Teleporter or other mobile aerial platform and lifting equipment. All terrain crane (depending on site) Chains and other small tools Road material delivered by supplier to closest convenient point (38 ton gross) Crew size: Generally 3 workers

4.5

Traffic Management
A traffic management plan will be agreed with Kerry County Council for the duration of the works. Traffic Management will be in accordance with the details contained in the Environmental Report and recommendations of KCC. Construction traffic will comply with the local traffic requirements and in agreement with Kerry County Council road engineers.

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Traffic Signs Manual issued by the Department of the Environment provides details of the traffic signs which may be used on roads in Ireland, including their layout and symbols, the circumstances in which each sign may be used and rules for positioning them. Chapter 8 of the 1996 Traffic Signs Manual will be used on this project.

Local groups will be consulted in advance of works: eg. local schools (bus routes) and local residents. Dirt on roads; If required, a wheel-wash shall be installed within the temporary works compound to wash dirt from the wheels of road trucks transporting spoil off site. The access route shall be monitored to ensure no dirt accumulates on the public road due to the construction traffic and cleaned if required.

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Waste Management
All waste arising during the construction phase will be managed and disposed of in a way that ensures the provisions of the Waste Management Act 1996. A Construction Waste Management Plan will be implemented to minimise waste and ensure correct handling and disposal of construction waste in accordance with the Best Practice Guidelines on the Preparation of Waste Management Plans for Construction and Demolition Projects, Department of the Environment, July 2009.

Waste Manager A member of the construction tem will be appointed as waste manager for the construction phase. The waste manager will have overall responsibility to oversee, record and provide information to the relevant authorities on waste management for the project. Authority will be given to the waste manager to delegate responsibility to sub-contractors where necessary and to coordinate with suppliers, service providers and sub-contractors to prioritise waste prevention and salvage. The waste manager will be trained in how to set up and maintain a record keeping system, how to perform an audit and how to establish targets for waste management on site. He/she will be also be trained in the best methods for segregation and storage of recyclable materials, have information on the materials that can be reused on site and know how to implement a project specific waste management plan.

Waste Types Bedrock If bedrock is encountered during excavations, it will either be crushed onsite and used for infill during construction, or be removed from the site by licensed contractors under the Waste Management Act 1996 and subsequent amendments, Waste Management (Facility Permit & Registration) Regulations 2007, and the Waste Management (Collection Permit) Regulations 2007 and disposed of off-site.

Soil/Subsoil Soil will be removed during excavation of the foundation areas. Excess inert soils and subsoils excavated that is not required for use as fill on site following discussions with the landowner, will be disposed of or re-used offsite.

Any soil removed from off-site will be carried out by contractors licensed under the Waste Management Act of 1996 and subsequent amendments, the Waste Management (Facility Permit & Registration) Regulations of 2007 and the Waste Management (Collection Permit) Regulations of 2007. The volume of waste removed will dictate whether a certificate of registration, permit or licence is required.

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If any soil/subsoil is deemed to be contaminated it will be stored separately to the inert soil/subsoil, sampled and tested. The material will be appropriately classified as non-hazardous or hazardous in accordance with EU Council Decision 2003/33/EC which establishes the criteria for the acceptance of waste at landfills, before being transported to an appropriately licensed facility by permitted contractors.

Metal Metal is highly recyclable; there are numerous companies that will accept these materials. A segregated skip will be available in the site compound for storage of metals from site pending recycling.

Hazardous Materials During actual construction activities, on-site storage of any hazardous wastes will be minimised, with refuelling and oil changes carried out on a regular basis off site. In the unlikely event of any storage of all hazardous wastes on site, this will be undertaken so as to minimise potential for environmental impacts.

Non-Recyclable Waste All non-recyclable wastes will be transferred to the site compound at the end of the working day. In the site compound there will be a general skip or other receptacle provided for non-hazardous waste not suitable for reuse or recycling. This skip will include general wet waste (mixed food waste and food packaging), polystyrene, contaminated cardboard, contaminated plastic etc. Prior to removal, the receptacle will be examined by the waste manager to determine that recyclable materials have not been placed in there. If this is the case, efforts will be made to determine the cause of the waste not being segregated correctly.

Tracking and documentation procedures for off-site waste All movement of waste and the use of waste contractors will be undertaken in accordance with the Waste Management Act 1996, Waste Management (Facility Permit & Registration) Regulations 2007, and the Waste Management (Collection Permit) Regulations 2007. This includes the requirement for all waste contractors to have a waste collection permit issued by local authority where the majority of the contractors business takes place.

If the waste is being transported to another site, a copy of the waste permit or EPA Waste Licence for that site must be provided to the waste manager. If the waste is being shipped abroad, (in this unlikely event) a copy of the Transfrontier Shipping (TFS) document must be obtained from Dublin City Council (as the relevant authority on behalf of all local authorities in Ireland) and kept on site along with details of the final destination (permits, licences etc). A receipt from the final destination of the material will be kept as part of the waste management records.

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Reinstatement of Land
Once all works are complete, the access route and the construction areas around the substation are restored to their original condition or better. Generally this work is carried out by a specialised agricultural contractor and is carried in accordance with the relevant IFA agreements and in consultation with the individual landowner.

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Summary
Construction of the East Kerry North West Cork Project can be summarised as follows: The substation construction activities will take place at a fixed construction site Work will only be carried out during normal working hours. All planning conditions will be implemented and contractor will be supervised and managed closely to ensure full compliance. Duration of work at East Kerry North West Cork substation will be approx. 12-18 months.(Subject to agreement post-planning with contractors and ESBN)

Note: This document should be read in conjunction with the overall Environmental Report and its specific recommendations for the East Kerry North West Cork Project.

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