FI"ELD TESTIN(; WIND FARM' AT" RAS (;Hartebl

RENEWABLE ENERGY RESO 'CES FI"ELD TESTIN(;

CONCEPTUAL DESIGN FOR FITLD TEST 1 WIND FARM' AT" RAS (;HARtEBl

JUNE Y"986

1II AL

Prepared for

Egyptian El.,ctricity Authority Cairo, Egypt

U.S. Agncy for Inror nat ional Dev,'lopme'nt USATD HI.s.ion: Cairo, Egypt

Sibmitt,:I to

Louis Borgor Int.ornatlona, Inc. Washington, D.C. (Contract ALD 263-0123C-00-400 9-00) (M. r idian Task 'No. MIC-1/3-396)

Prpard by

Nor idian Corporation Falls Church, Virginia FO REW0 RD

The Egyptian Electricity Authority (EEA), United States Agency for International Development (USAIP/Calro), and a group of U.S. c ulta:nts forif

a team responsible for conducting Mid test dacon'trnt on pz'ojects for Pleven renewable energy appLication; in ,ypot. Tlese dev:oai:,tion por"jct:; includi

the use of photovoltaic, wind and oar thirm syntns for ,t:r pumping, ice

imaking, desalination, industrial :rocc s ,at: and grid connected e.triy

generation. The specifi.c . 4 objct ives oF th -ye.r prv..r2:m are: (1) to du:moen trate

the viability of renewable ,nerV t,-chaoi::gfes in Lq';. (2) to comprehensivelx

strengthen Egyptian techaica] and &nMt MUt onal, capnalI i:LOVS In the full spectrum of renewable energy planning and decis on m.king, and (3) to cstablisah the

infrastructure necessary LO ensur, tia .'acable ,nr.,v t-.chnoloSie, which

have proven successful., are ava.l1ablie for wides pread une iQ Egypt:

Three of the eleven potential field test deonr5..ration pro jecs are wind

energy system applications. Each of the field ,-t5 con tains savea L neric tasks:

Technology Review, Application lovew, (onceptual Du'slgn, Preparation of a S tate- ment-of-Work for a Tender Docummn, Pra v-al v.,t'alata a, Su pervis.on of Hardwar.,e

Installation and Perfornance EvaA- on. The Conceptual Des; gn for one of these three field tests, a grid-connaated wind farm, inapresented in this document. The proposed wind farm is sited near Ras Ghareb on the Red Sea and will consist of multiple, int:ecccnnectroK turbines with a total peal: power of approximately 250 1 kW. The system Is de. ignad t:o opr r: in a fue -naver mode for an existing power station and provide elect riltv Lo aa exis :ing transmi sion grid. This document is Subtask 3.11.3 of the field test requirements under

Contract AID 263-!23C-00-4069-00, Task Area 3.

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This document presents the conceptual design for Field Test #1 1, a 250

kilowatt wind farm at Ras Chareb on the Red Sea coasL. The general concept of

the wind farm is to generate oloctricitv that will b ed into tho e:i.sting 6.n

KV grid at Ras hriarh. In this manner, the winl farA: isa essentiallylv ;,; ,,od

in a " oFul-s avor" made, . .e. th, oil .andn.asfir,. tuibin,,s currn.o t , uq;o:A to

1pnerat, electricity will ave thoi r r'in-timo reduc'l hecauso th- win.t-.,n,.rat., d

electricit, will moot part of the Ras (hareb demand.

The results of this cwncoptual dIesign st.,y tLo size the wind fan and to

provide specifi:,.tions for a tiLde.r ,COum,,nt and a s;'t m acceptance test are:

o naximum si:o of ipp:.:Innt" lv 400 kilowatts; rated poaer o inimmn siz, of pI: 2.:l0a h i2 t t y ratod powor * T 'b i n -, . v a i hL I~it v o,C 0 :I ,n(r c. n t

* M:in i!::,: -III r, a! e':,rnv prod ,um.i:,;on ,of 62 5,Ond ki ! awat t-hnurs; It should he noted that thh o ification for a minimum annual energy

production will be revised for the r- lease of a statment-of-wnrk in a tender

document based on an updated wind re;ource assessment provided by Battelle

Paci. ic orthwest Laboratories.

The c-a ld: ato wind farm nonceptua:lized in WhiS document consists of five

50 kW wind turbin-s interconnected through a single control box that generates

250 kilowatts of power at a rated wind speed of appr Wxinatolv 15 maters/second.

One possible turbine uses a 6.7 moter (22-foot) fixed pitch rotor, the simplest and most reliable rotor des iqn option. To work ,effectively, the fixed pitch rotor must operate at a relativelv co stant speed. This can B achieved by cnupling the rotor to a 3-phas, induction generator Lie di rectLv into the utility line power (after necssnar prntoction switohgear are used).

The wind turbine in this example employs two separate braking systems to greatly reduce the possibility for a single failure to cause a hazardous situation.

Tip speed brakes are employed that automatically limit rotor speed to negate an

1 overspeed condition. The speed brakes are deployed mechanically by centrifugal

force associated with an ovorsp owd (onldiLoion. The primary braking system, however, is a two-stage electrodnamic brake.

The five turbines can be mounted on 30 foot (24.4 meter) galvanized, self-supportin., stee litt ice towpr;, however, care must be taken to insure th-t the tower can withstand the apparentty corrosiye enviranmrnt at Ras Chareb. This type of tower is a rensonahle romprom i hotwe: ,no of main enncne, const, and potentIal for local fabricatinn in future installations throughout Egypt.

An engineering cost estimate for thin posnib!, wind farm iq presented in

Appendix A. BB-1

e, m es

e ip tuUUA~ u

All ~ -W ', In be r , arwe ea v~ n I a

-mna,,",E area

C~he z e ,, a Qs 0 r-. r- DweeQ nd:pma,,1s uape i -'h wrj e a e-a c 'T. anc ev a daa - g 9 t see C)za11U8C C pC aI * 'asupo~n .!n iss --;- ndd auac aj_,s a andi a~t'n Iee scCae

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On SB

anr: e a. ea e I

p oexls dg ,berlsu n pr ov a ar~

deada se' s a"iea r esez ysetd ylsa a t.ealCae aq e che,-sihb flcn grqwhFh , a ndV

maDo e s e a,

eir n es. turbines (wind farm) interconnected with a local elact-iical grid dint r biit-ion

s.s Iern. The Egypt: !n E.e,. tr.ric t : indIhoty (E /.,) d 'A ID/C, i.ro ,; ta i- (shed

that the peak capacity of the wind farm hehold appro::im;telv 250 kilowatt:,;.

71,,e proposed locLon for t:he a : ,2ws the10. vil lage of ,n Charob on the

,ulf of Suez acroa!s from tht- :fi ,tof:i:rn the Snai, approxlmat.ely 320

kilometers frorn Coiro (Appndi:x B) 'Ilit, .yst('tm sini n and snpcI fic location

for this fi eld test were bt;.; on a pr] :iina' anoal, o r,,T, :w i n Eypt:

where s:oh I e ,,, i,ir ds and on hi storza!. Iv ;rod wimadreource co-exist:1I.

'TIese factors were at o : Invein d itai 'i ir :',, a st e vi.-iL 1y personnel. from

the EEA and the 1 the U.S. Proj 't, T-am, n )- 1 ,51 An analvnis of the

application hased on dot a hto alne ti uini, the site vi sit is prItsented in the

Field Test II1 App]icattonP iew aubmtted on February 5, 1906.

2.4 Intent of t he Co:iceptuil De(;i, n

The Conceptuial Ees- n : ,it:a:: evolves from acti:vit.ies in support of the

Application Review, the Te c hno oi0 y Rev!ew and t:hL identification and quantification

oE system performance spccl fic.t.io:in, and hardware specifications where appropriate,

which will become a major port ion of the ,tateme:ut-of-W, rk. The A:nua 1 )per ag Plan (AOP) for the REET Projac: , dited Ha 1905, , poCifanI that . th. cI opto

dnsign activities "est.ablish tocniacal objoctives, develop a svstem design data

bose, and screen candidate vn tea '' n tolag"o .t and

operating baseline that satisfies site-!;pecific operational, environmental and

user requirements."

1 In attendance for the U.S. Project Team were Peter Borgo of Meridian Corporation and Seyoun Solomon and David "Iylcrof Louis Berger International, Inc. In attendance for the EEA were Eng. Mohanted . twaI[lv El-to ved and Fng. Nagi Gowl I Discussions were held wi th Eng . Ih rahin Aly , the Area (;eneral Manager for the General Pet ro leuim Company (CPC) , Fng . Wahid Mal,bouI i , a :ianaae r i:1 t:he Electrical Engineering Department for GI'C and va rous members of heir s taf fs. Specific subtask statements in the AOP specify that the conceptual d, [i.t

shal L :

o Develop site specific energy source profile and application specific load d tm:ind pro:ti

o Define hardware p'r-Forntance and environmental specifications

o Conducm s ." t t s i:'.ing and p >rformance trade-off ana v'seos

o Specif molntarin insuru ntation rerqu:iremonts.

These tasks were compiLted as part of the Application Review and

Technology Review activiti ,, in conj mction with visits to the U.S. of Egyptian engineers from the EEA and the Ceneral ottrOloi, .ompany, th, future operator of the wind farm. Elments of the conceptual .i.ci:n do scr ib e in this ocu t appe ar in the Applicatin P.'vKow and the Trhno Ioy ,-vipw submitted in Pruary

1986 as fotlws. Appropria te data from these documnts wil.l he included in the

Statement-of-;ork ( SOW) for this field totest

o A site specific enery outr.., profile and an ippli cation specific load demand profile ar. ino luled in ti- FT Y1! Aplicat ion Review

* Hardi., ' nor Forina' cpc," anl a,'"iren : n tal spec.i ficat ions ar, included in FT the A:ll Apr 1i cnCia A&! Y T It Io l b is..';

* System sizing an,& trt'd,'-of f analys's are su:marized in the App!ication Review for FT ali frEm data pihlbshed as a sep.rat, docuintI in August 1985

o Field test monitoring instrumentation requiin-ments are included in the Technology Review for F'T .1 I and Appendix C of this docum::ent. 4~ ;_Ki'

...... '4Y

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17.

V 'MO

Al a' region. If wind power is a viable alternative energy source, the EFA would

re-allocate existing gas t urbine generators to balance regional electrici tv generating capac i Ly as wind generated power comes on-i ine.

3.3 Size and Stability of the Local Grid

A large , stable power qe ne ration/distribution grid exists at Ras Ghareb

which should he ahl , to in!-rface with n 20 kilowatt wind farm. There also

appears to be suffficient I.oxihili ty in the existing power .;onerationmix to

incorporate wind systems as they come on-line.

3.4 The Wind Resource at Ras Ghareb

There are two major historical sources of wind characteristics data for

the Ras Ghareb area which indicate an average wind vlocity of 6.4 (4 month

average) to 7.3 (annua averago, met eri/ second. This is a sufficient wind

velocity for the generation of elctrichtv using wind turbi.nes.

In general, a wind resourco is very site depe ndent, both spatially and

temporally. Therefore, it is very important that wind velocity data b validated

and collected as near to the actual turb ine site as possible and for an extended

period of time. In support of Field Te st 011, USAID/Cairo has contracted with

Battelle Pacific Northwest L:boratories to conduct a Wind resource assessment

of Egypt. Mea surements have been recorded ,sc the proposed wind farm site since

March 1985. These data will he analyzed for a period of one year.

For the period April - Sept cber 1985, these data indicate an average wind speed of 9.2 meters/second at 10 meters abve ground level and 9.6 meters!

second at 20 meters above ground level. This is an excellent wind resource and

is comparible to areas in Cal.ifornia where commercial instal lations of wind turbines are found.

8 3.5 Availability of Proven and Reliable Commercial Systems

Due to the intermittent nature of. the wind, the genor'nt'ion of electricity

from the wind will vary con;iderably with time. As a result, wind generated

electriciL should supply only a s::ill percentage of : yiven load. in general,

the size ot a wind farm i:; "us.<;alivlimited to betwo,,n 10 and 15 percent of a

user's load domand. For the Ra; (haoh application, this results in a wind

farm with a peak pawer of appro;:iumately 250 to 400 ki lowatts.

A pro Iiminary winidn farm cone'iuai 0 's ign S in i o_ study was compl'ted i.r

Augus t 1 Bas

overall RtEFT Project objectives, it is proIose(d that the first wind farm field

test demonstrint ion in Egypt he an installiation of a rasnna; Ic ntiohr of inter

connected and c omm)ionly controlled turhi nes connected t:o oa taxsting; electrical

grid. Therefore, the Has Charb wind farm should con;ist of betwen 5 and 15

wind turbines each proluci.n be tween 20 and 65 kilowatts peak power for a total

of between 250 and 400 kilowatts.

All of the hardware systems required to complete a grid-connected wind

farm application are technologically mature, of proven operation and commercially

available.

3.6 Salient Issues and Needs

The proposed wind farm site at Ras Ghareb is located along a ridge line

at an elevation of approximately 42 meters above sea level. The site is in a

treeless coastal desert region and presents an unobstructed view to the prevailing northwest winds. Site prepairation in the Form of civil work to level the site will be required. An access road capable of transporting heavy equipment

(turbines, towers, cement trucks, cranes) will also be requirel. A soil analysis should be completed as soon as possible to provide data on soil strength so that an assessment on the specifications and cost of the road can be made.

9 Also soUi strength data will be roquirO d prior to the pr ,paration of th,

statement-of work so that bidding contractors can accurately cost the turbino/

tower foundations.

A key factor in the success of a wind farm fi.eld test demonstration is

the ability oF the host organization to successfully perate and ma intain the

svstom. The GPC .ngin no rs nld technc ate nns accuntnod to , int,* ai1. n l argo

rotating machinoy, both m.Za' w;:tt in, a:is hurbines al numeious diose! engi:nes.

They also hao installed and ,int inu to m:iintain the'r own .ol.c r ical tran mi sio

grid, including transformers and switch gear. With sufficint training, which

is a part of this field test, it is expected that GPC personnel could operate

and maintain a wind farm.

3.7 Status of Agremnts and Rspons ib1 Agencies

An agreement has boon s i.-ed by' AE and CPC io;arding responsibi lities

and approval for the wind farm at Ras Gharb. A re view of these agreements

between I'SAID, the EEA and the GPC h:Muld be undertaken to insura that the

decision to proceed Or not wi.th this field test is bansd on an accurate appraisal

of the existing situation as spe cified in this Conceptual IDes ign doci;aent . This

includes concuirence by all parties that the fieLd tent as specified in the Field

Test #11 Application Revi.w is accptab Ia, that all iesponsibiIi tis of participant

are clearly specified and understood, and that requiied site pIreparation and

civil works can be completed in a timely fashion.

3.8 Conclusions and Recommendit ion

The findings in the Field Test #l1 Application Review support a strong recommendation to proceed with this field test demonstration. All the necessary criteria for a successful wind farm installation appear to be satisfied at the

Ras Ghareb location as follows:

10 1. The curt ent ar: futtur, lo :tric itv needs of the Ras Ghareb reg ion 4 are supplied by a 21t l gr2'id thnui shond be able tO , .lcP t a 250 kilowatt winl farn.

2 . The wind re.sourci :eis o l .,nt, av1 ,r1. 9.6 mnot ,s per sec ond at a 20-motor hi L fr A,WKI thrgh O,,i Lonor 19685

3. Svstemi hardwaro that: is proven and reli-a le is available from

4. There duos notL appear to be any difficulty in sit ing and instal.ing, the wind ;.t..in hardware at Ra s Ghareb.

5. There appears to b, a cadro of enginoers and technicians employed -y the local PC opor-ttion; that can be trained to opernto an.1 maintain the wind-armn

Recommendat ion

I. A grid-connected wind arm of approximately 250 kilowatts should be designed, purchased and installed at Ras Ghareb.

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5.1 Design Approach

In August 1985, engineers from Meridian Corporation, the EEA and the GPC

conducted a joint analysis to investigte the desired si:e and estimated energy

production of a wind farm at Ras Gharehb that would satisfy the Objectives of this field tet.2 The study me ,,lho ,. to evalunte th pvrfr i:;nce of wi&n

turbines manufactured by ci fferent U.S. companies in the wini re:;ource measured

at the !irbor Station at Ra; Chareh In 1983. The evaluatton was, prformed

using a wind system perfo rmance compr'ter model developed by Meridian Corporation.3

A wind farm si.ng limitation of h:,.een I0 and 15 percent of a base-

line load demand suggests a. .iximum w'.: ; :; c ,.eapproxi matelv 465 Fil:owat'ts

for Ras Chareb. A mre consrvat ive sizc would be 10 percent of the average expected minimum power deman d or oppro::matel y 250-275 kilowatts peak. ibis

limitation will be investigoted fOr the Pas Ghareb application by careful

monitoring of the voltage and frequency s::ability of Lhe grid durilg this field

test as wind generated power is introduced.

Using the singular measure of peak kilowatts of wind generated power is not always sufficient to determine the effect of a wind farm on a particular grid distribution system. An- equally important parameter is the level of energy in kilowatt-hours that is introduced into the distribution system at any given time.

For example, a 10 percent wind energy component of a power generation mix (based

2 Estimated Power Production From a Wind Farm at Ras Chareb, Egypt, August 1985, Egyptian Electricity Authority, General Petroleum Co. and Meridian Corporation.

3 "Wind Energy System Performance Model-Users Manual," March 1983, Meridian Corpo ration.

14 on peak kilowatts) can have a lare impart on total ener y pr ohc.1d ( in kilowatt hours) during periods when thoro is a low load demandnd 'nd th, .ik ''olocttV

is high. Consideration mu uh given to the l"v 1 l -nh varijabiiit, of :I rolativelv

continuous base liie load dmanod for a s pec ific applicat Lon wh,,n the wind svst e:

component is heingsized.

In summary the resul t; of t:his conceptual dos in study are:

o Max iIippS, . eL1 :.:i1.ir.0o v 40( I MIi.:11 11111:u : s [Z e ki1 owatts " :ted pv,er , o t "Iv:: ::::,I ,1::: : : " .): : 1 1..... Li I ,W :., ,-. rite I par O T u': 7 , %7 1: 1,1', '_I r t 0 ;1 I:.1 :l 11:11 [1 . y Io : ) , wnaL- t -hI ,r S

it should he nO t dL hu : tI ,-1,0C i K c:I t:ion f r a : i:nI!n a ln enrgy,'

product ion will he revi ad F..,r thIe r Ileae of a tt ','.,nt-of-worI (Srg.:) in a

tender doCUlel(nlt lased onn ;t , 1:pdated ,..i.nd resource asse.; s ,n Ir, vided byI Battelle

Pacific Northwest Laboratorios.

Additional factors in the conceptual des ign approach are tie cons idc rat ion of the performance and 'envr,,nment:i ecifications that the system hardware

must meot and the me thiod to be us,?d for a sstern acceptance ost. The fo'lowin ;

are specificat ions that inflaence the conceptual design. They wi l appear in

the Dra ft-For-Comment copy of the Snw.

Energy Product ion and Sys Ltm Accptance Test

hinergv mroduction from the wind F-i, usntut)e demonstrated by oporation of the wind farm with on-sito contracLor personnol for an acceptance Lesting period of 30-daNvs after it ids.gnatal op'rational Pv E!IA/ySAl. This dosifnation will be based on the contract-r's certi ficat ion that the wi nd t-urbines and control Svs tem are operationo , and tho EFA' s cert ificat ion that the interconnect with the existing grid is completed. The wind farn mut achieve 90 percent availability during the syste::i acceptance test.

In addition, daily eoner.-,' production for each turbine during the continuous

14-day period must be no less than 907, of the ianufacturers perfortsance estina te

15 provid.ed in rho proposal. Th. po forman,. conpar ison w LI be based on oasuyod

aver agie daily wind spod fo o h applic'b],l +toa.11W in' the 3)-da, pr "o man:-. period. A curve such a.; that shown in Exhibit 5.1 will bo us,,, tW compare th,,

mlnu ctLur ;~ or'S .rormanw:o sp0i: i cit i Vor orch turbine, with th., o'; surod

powo r pr o.uc t ion.

Co.trol J n.

Th,, wind torhinos shall .'mp ov: fail-safe, controls to pr otect tho rotor

from ovrsp'odiW4, winds in ;i,,ati tLan its iitd spool. The contr ol s v- tjn

sha!l providO for automatic startin; whon rho wind spool rachs cnt-in voioc y,

The control s,'stem shall also pro'ide f:' automatic restartin g when the wind

speed drops be low the cut-out,Valu. A manual control for shuttin;; the machine

down to allow for system maintenance and repair shall ho a part of the control

systeim.

Electrical Tolr ancos

rh followi ng to!Prances must be met to be dolivor power of acceptable quali ty:

Fr eq uency 50 Hrtz + 0. 7 Voltage 380 volts + 0.5'' Power Fa'or minimum of .2 laggitng (approximatelv L ,',ox. t: : .' .;",0 power factor at RA; I:loh) Ha rmon i cs Maxim of' Mf tILo furamenta I

Electr ical interface

All elctr ical conneLc rs and tormin:al: incOW,, na slip rings must have high resistance to tomporatur.-, dust, and COTmoS ion. Q hr factor; such as lightning arrestors, and safo.' fatur,.s (breakors, fusas, etc.) must be compatible with lEEA *lectrical codes and be located at ground level for easy operat Lon and ma intnanc,.

16 Energy Production Specified by M-,nufcturer

z 10 0 I- o .rr',CC 2-,roduz.:!on3 u 5dt ?o114r70.. f'L. 15 0

-J

Ex-h ft,5....-.1. 7_

LLL 2J I t Liliyffi ! I 1 2 3 4 5 8 7 8 gl 10 ii 12 13 14 15

DAILY /' v -r" G-=,W FDSPEED ' /S)

ExhiitTh~3.NE 51. ~3~3F ThAA~C VE,' !CA TI O The system design shall include installation of utility lines an!or

conduit pipes to the point of connec iou to rhe exist ig lines, including a ll

transfonr at ions t:'r)] i str ibui ion to it Al i:a:,ion vot'a'e as;o may, ' b)0 co'q ui red,

Site Plianning and (onsnriction

The syvs t:em desin shatll indicrate minimum soil cond i tions which are

necessary for the propesad dos; inn of t.ho fonundat ions, earthwork, and dra inage

and methods to prev,,nt or ini in:,,eros on.

Environmo ata ,'IC i. i c qnditions

The propos od wind aarm i. 1 1 op,. rate in the w: nd 1 teipe rature and tum id i ty

conditions specfiehd bo.,,. The des ign shall describe in detail measures that

would be taken to protect all hardwarn ins tal'led in an envi ronment of airborne

dust and sand and a salIt spr-ay' typical o:f ne:i rshore applic-ir ions . ,easnreos to

protect har wa r for a sul phur on''i ronmonnt that rauiLsos mode ratL, to sovert

corrosion to unprotected and siinplo g;lvanizod metal.; shall be part of the

system designs. All parts shall he certified to withstand theso conditions for

the 25 year life e::pectancy.

o Wind: The wind turbine shall operate in wind speeds frmn any direction

of up to cut-out wind p,,ed for the turbines proposed. The t urbine ant

tower shall1 be capable of wi thstanding wind .oos of up to 54 mters/

second wverage I ov-r a period of 15 minutLS.

o Temperature Range: Ambient air temperature range of 0 to 45 degrees

cent igrade.

o HUmidity: up to 95

5.2 Operating Ccncept

Theo .,norn cnncopt of the win. fann is to generate electricity that will be Fed into the e':isting A,.6 KV grid at Ras Gharob. The proposed wind Farmt is small enough (250 kW minimum, 400 kW maximum) to interconnect with the grid at

18 a single point (?xhibit 5.2). Each trhin has it; s.parato control instiumon

tation. Cato must: b ,x.,r .;,, t,o:0ipto i ne i suffj:.icfi.',? : el c rical prot.,ct i,)

devices; in the interconnoct isolato to eich par : of the stom in cao, of failure

along, tho Lino,. Protect iv,, ',,i.:, which .so..pirimol-r, such as voltg., . '" .'Is.

cur ronL lov. is, fr oq uncy and phlaso squonco on the po.wer i ne must ho used to pi on.,ct tho turbines, trans:; former , t nsmiss ion lines:; and mainte nance p.ersonne l.

A systom conr-ni and perfrm: nco moni torin-; .v.tem .s also re*quired:

( .hi bit 5.3 ) The pe formia c,e : nit_,r i system i:;s ,lepFId IL of the. t urhin

control system. A failure in the munitr ino;system m st not affect tho overall

operation of the wind farm. Sp.cificat ions for this system are incl.uded as

Ap p. nd ix C.

Generators us.d in wind CUrhi nos are one of three standard type:

snchronnus g onerators, commonly reofer red to as alter nritozrs: induction generators;

or direct currtnt (DC) generators. S'nchronous gonOritors (alternators) prodiuce

an AC voltago at a frequenc. that is P oport ional to s;haft speed. Even i th rotor speed rgulation thor will still he enouh of i variation in frq,,ncy

and phase to pivont connection of an alternator diroctlv t Le utility grid.

Thus th,, alternatoar i s a Ilowed to ri n at Ii ferent so; . ; pr oduc in, a ,.ar iable

frequency output. The altninator output is thn rect ifiedt, convertin:g it tco

DC. The DC is fPd to a synchrnonu:; inverter, at a iine fr'quencv output that

can e connected directly to the utilit, ,;w id, With th is confi;uration the

need for a transmission to coanoct the rutor and generator is eliminated and

the a lternator can be connected directly to the rotor. A diagram of this configuration is shown in Exhihit 5.4.

An induct ion gn'rat:r is;woell suited for grid conn ccod applications.

They are s;elif-r.n',uil titng, in adju:;ting to varying torqu,es an-I load conditions, and can ac': as motors for rt, Lin.,;. A picture of th i sys ,temis shown in

Exhibit 5.5. As a result of their sim'plicity of dosi:;n, operation and control

19 -- R I 1 N

C 0 HT OL BOX M©IOFN SYSTEM T , DATA j CORCLIT D E AKEA TRANSMISSION FO 7TRAN'SF O RPER

PP,R0T TON10

4 VA C 50HZ

S EP-UP , RmER

Cl~iCUIT 5F-:E A Efl FOR P.';? - "U SION

LINE PFOT ECTIONJ

tII

Exhibit 5.2 WIND FARM INTERCONNECTIOrJ BLOCK DIAGRAM PROJECT OFFICE COMPUTER

PHYSICAL

UIDD , TO ".. TRANSFO RT CONTROL . N.,I OF MICROCHIP CBONXRG LINE (E P R 0 M)

CC,'.ITROL HOIJSE

SYST,,E:M

I!(OPTIOr'AL) _ . . .. V*..

BOX . ATA

Exhibit5.3 CONTROL. AND PERFORMANCE MONITORING SYSTEM

21 Exhibit 5-, DIAGRAM OF A WECS LISIhJG A S'.iu"CHRONOUS ALTERNA TOR

Fro-ency oc dc Voltne

WindUlili G ' o S yr~hr Vw

Exhibit 5-5 DIAGRAM OF ,EC!S W7IoV AN !NDUCTOi G&VERATOP

LoLnSpmtd Hip S~wvd

Gc T rlrm .n ll Cu o r, Grido "----*- L L rrt

ac Pnwerl

Exhibit 5-6 DIAGRAM OF WECS USING A DC GENERA TOR

Wind

22 most grid-connected wind farm applications currently use induct ion generators.

The typical induction gen'rator, without power actor correction. wil l have an

average power L-actor o 50 toi 65 prcent when it is opo rat:ed over viryin, power

and speed condt ions. With the ue o a capacitor bank, which is an int egral

part of the power ,oenerat ion sect ion, the average power factor can be increased

to 85 percent or greater. T'is would he an acceptable value from a it ilitv's

poinat of view.

Th,e final method used for generat ing utility grAde AC power is by using a DC generator with an inverter. The generators used in such aepIications are 3

phase brushless alternators. For design simplicity a standard inverter is

located on th 2rounid adjacpin to the wind turbine. A DC voltage regulator is

required to ma:intAi n , cons stent input voltage to the inverter. This arrangoment

is shown in EiA it 5.6.

5.3. System Configuration

5.3.1 Turbine Specifications and Performance Parameters

The candidate cinceptual vi nd farm for this example consists of five 50

kW wind turbines interconnected through a single control box that generates 250 kilowatts of power at a rated wind speed of approximate.ly 15 meters/second.

Exhibit 5.7 presents specifications of a typical wind turbine system.

Many possible turbines use a Fixed pitch rotor, the simplest and most

relio)le rotor design option. To work effective ly, the fixed pitch rotor must

operate at a relativelv constant speed. This can be achieved by coupling the

rotor to a 3-phase induction generator tied directly into the utility line

power (after necessary protection switchgear are ued). Induction generators contain no slip rings or brushes and no rotating windings . They are very relia le wiO an operating efficiency typically over 90 percent.

A typical turbine uses 6.7 meter (22 foot) rctor blades which are con structed of wood laminates and epoxy resin and covered with fiberglass. The

23 SYSTEM

Fype Utility IntOr f'> at 50 Hlertz Output Power & Windspo.,d 30 kw at lOm/s (22.4 mph) 50 k. at W4.75 s,!(33 mph) 55 k"at 2! .n m/s (55 mph) Axis of Rotor Haorizontal Location of Rotor (with rospect to tower) Dnwnwind Number of b lade 3 Rotor Diam ,ti 13.4 m (44 ft) I Hub Hei ht 25.n m (82 ft) ' '' t,s ' ' ',h t 1.' towe,) 1,815 kg,(4.000 Iis) (apprax.) c lu d in g 2 4 .4 in ' o ta l v,:' "' 'lit ( in tow,,r) (s0 ft.) 4,550 k (10,000 lbs) (approx.) 11hE1\ 0t1,,'-1-%",C,.'.DAR ' " '.e

CI t -In 1i: :1, !,' d 3.8 n/s (8.5 mph) 'i.d ' 25 m/s (55 mph) - 60 sec. averag,! i v ;.1',i d li',,d 5 4 ri's (120 mph) Sita iti i n Spood 5.8 ,/s (13 mph) - 6 s0<, . average Vhut-Dow Ji nd Spa md 4.) /s (9 mph) - 60 S' . SIVa,arg,

Exhibi t 5.7 Typical Wind Turbine Systemi Spei ficat ions

result is a waterproof, non-coriosiv, structure that will resist changes Ln

humidity, rot and insect (amag,. The tur bine can be a free-,w. downwind type

and use three rotor blades.

The wind turbine in this e>xample. 'mploys two separate braking systems to

greatly reduce the poss ibili ty for a single failure to cause a hazardous situation.

'1Tip speed brakes are emp1o',d thlat automai: Cally 1imi t rotor speed Lo nega te an

overspeed condit ion. The spood bi ak. s are deployed mechanically by centrifugal

force associated with an ovorspo.,d con:lition. The doploymnt of any two of the

throe tip brakes will limit rotor speed to saLf., limit! in any wirid condition.

The pr imary braking system For the turbine is a two-stage a.loctrodvnami.:

brake. The first stage is an AC dynamic brake whi,"h lowers the frequency of

the generator, thereby forcing it to slow the rotor and convert rotational energy to electrical energy. The second stage is a disc parking brake which

24 engages a few seconds after the dynamic brake hr ing i ng the rotor to a complte

stop.

5.3.2 Possible Wind Farm Layout

Th, layout of a wind farm must tako into account the nature of the

prevailing wind, the site topography and turbine rpacing and tower height

(Appendix D). For the proposed Ras Chaieb site, the wind is from the north and

northwest over 95 percent f the Lim,,. The selOctd ridge line is unobstricteo

to the prevailing wind and appears to have a uniform flow along the ridge at a

30-meter height. 5

The topography of the site indicates that site pi ,paration in the foim

of access rcads will be minimal. The distance to transmission lines is on the

order of two hundred mters. It is still beneficial to group the turbines as

close as possible to minimize interconnection wiring and access roads. Exhibit

5.8 is a tossibi . layout for the concoutual wind fa i . Turbine spacing in a

direction perpen(licular to the prevailing wind should be at least two rotor

diameters, in this case appro:x.im,,telv 26.8 meoters (3 foet). In the downwind

direction, turbine spacing should be approximately 10 rotor diameters to avoid

wake effects, in this case 134 meters (440 feet) 6

The turbines can be mounted on 24.4 meter (80 foot) galvanized, self

supporting, steel lattice towers (Exhibit 5.9). However, care must be taken to

insure that the tower is adequately protected in the apparent corros.ive environ

ment of Ras Ghareb. Selection of a tower is often made when a turbine is

selected because turhine manufactureis have towers designed specifically for

4 Egyptian Wind Resource Asse>,sment Project, Interim Site Data Report, April- September 1985; Battelle Pacific Northwest Laboratories; January, 1986.

5 Kite Anemometer Studies at the Proposed Ras Ghareb Wind Farm Site, Battel le Pacific Northwest Laboratories, February 8, 1986.

6 Meteorological Aspects of Siting Large Wind Turbines, Battelle Pacific Northwest Laboratories, January 1981.

25 T4 FEET 44 FEET (13.4 meters) (13.4 meters) Direction

I Prevalling Wind

440 FEET jf q (134 maters)

88 FEET ~ 64--~8~FEET (23.8 meters) (26.8 meters)

Exhibit5.8 SCHEMATIC OF POSSIBLE TURBINE SITING TOP PLATE TO BE SUPPLIED BY -1 TURM.'rE MANUFACTURER J7

--- SLOPE

/ CHANGE

L-LOD=TOWER DESIGN LOADING

~WIND LOAD =58 P,S F. W/E L.A STAND.'ARDS

THIS TOWER IS DES;GNATED TO SUPPORT 0 THE FOLLOWING LO.DS

K, ELEVATION TURBINE PROJECTED C4(FT) TYPE AREA (SF)

82 50kw WIND TURBINE 117 (2ABCVE APEX)

THIS TOWER IS DESIGNED -' TO SUPPORT A MAXIMUM i , LATERAL THRUST OF 6600 0. LBS. AT TOP OF TOWER.

DESIGN NOTE: TOWER DESIGN BASED ON STATIC LOADING CONDITIONS ONLY. HARMONICS AND/OR DYNAMICS HAVE NOT BEEN 1 " CONSIDERED 4 A-B01IJS (12 TOTAL) 'o I 1'," DIA. 48" LONG ASTM A-lB, GRADE B7 I I

Exhibit 5.9 80 FOOT LATTICE TOWER DESIGN DETAIL

27 the turbine system weight and dynamic loading stress. Many manufacturers will offer different types of towers however. This tower is a reas;onable compromise between ease of maintenance, cost, and potential for local fabrication in

futur. installations throughouit Egypt.

The tower can be install.ed on two types of foundations; a concrete slab

or "mat" foundation and a p ier-typo or "bell" foundato)0'. Exampl, foundation details are given A E:xhibits 5.10 and 5.11 for an 24.4 meter (80-foot) tower. The "General Notes'' in the e:hibits t specify that the foundation design assmies

"normal soil" conditions. Specific soil conditions for the Ras (hareb site must be analyzed before foundation specifications can be completed.

5.4 System Performance

System performance of the wind turbines will be measured in accordance with system acceptance test requiremcnts that will be specified in the field

test statement-of-work. These requiremn>nts were summarized in Section 5.1. As an example, the monthly power production for a 40 kW, 60 hertz wind turbine was

eCtimated using a computer system model and 9-months of actual measured wind data at a height of 10 meters above groun1 level at the proposed Ras Chareb wind

farm site. Results are given in Exhibit 5.12. Approximately an 13 percent

increase in power production over that shown could be expected with a 50 kW, 50 hertz wind turbine.

Capacity factor for the candidate wind turbine is the ratio of the kilowatt-hours produced given rh, measured wind speed to the kilowatt-hours

that would be produced at rated wind speed for the same time period. Also note that the candidate wind turbine produces 9.4 percent more power in the actual wind frequency distribution at a 10 meter height at Ras Ghareb than would be expected if the wind speed was Raleigh distributed (140,488 kilowatt-hours versus 128,371 kilowatt-hours).

28 TOWER AXIS AND CENTER OF PAD

CIRCLE DIAMETER

U XL \ 0 LL5INC-i 4 0 INCH LONG DIA. BY ANCHOR

-~.--40D , -- ~~~~~4-- _ _=, , EG F OHLTrQJALLY" SPACED)

- 120 DEG. TYP. OTEAL AELHOR BOLTS -P.E A- 1. A'E B7 AND ,"-SI- :ffLz IH ZG AT T IE L 7TOM A ',CHOR [ROLL PPDJDE'1co, IS 8 0 ;,' £HES -',Bt'VHE TOP E f E DRICONCRETE

5 IFT 91N4.

PLAN VIEW 19 NO. 7 HORIZONTAL P N E. W12"0 C EACH WAY. TOP AND BOTTOM GENERAL NOTES G L. FWY O ,DBTO I ASTM A-615 GRADE 40 DEFORMED FIEBARS. 1.-a.. 2 COCRETE 3,0 P S 1. ULTIMATE ST2PENGTH AT 28 DAYS. MINIM3U IIMUM TYP. 3 ALL FORMS MUST PE REMOVED FROM CONCRETE REF ORE PLACING COMPACTLD BACKFILL. 4 MINiMUj COINCRETE COVER ON ALL REBARS IS 3 INCHES 5 FOItATIOt DESIGNM ASSUMES EIA RS-222-C ELEVATION VIEW NOi,.1AL SOIL NORMAL SOIL IS DEFINED AS: (A) C01lE,;SV:[DRFY SOIL ID) ',:;:;IVE R'E:;ISTANCE OF 400 PSFiFT OF DEPTH (Cj Il I 'S F TiEARING CAPACITY

Exhibit 5-10 MAT FOUNDATION DETAIL FOR AN 80 FOOT TOWER V CHAMAFEn

0 .., SF 1J .

- -'NO. 3 CIRCULAR TIES - I I? IN C. TO C.

-___:-L_ OER AXIS

"/" FO ND T t-LE AT O 8 VERT. "/A10 /r. OL 1-- --2--CRCE IMEE GE(EQUALL SOTESCE-)

" 0S I E L EV AMU TI N- 4L.0 IW N.L T

2~~IRL r'ZE?*EPAL NOTES 3,, fDIAMETERT QP A.Y I ST -65GUADE 40 DEFORMED REE3ARS. 40.0 IByLNGACOM.-

IALLI7)nkiS M!)21 T1E REMOVED FROM CONCRETE SHFONGTATI-D :I~~G 4 EN;OREl~PC r,- Ec CO VPC ONDA FLLE A SI SPACED) NOTE ALL ANCHOR BOLTS F ND AT N 1) J ASS 4 A LMD; B; A RMS uIS C O N R E I £ C V E R N JMES. EIA RS-222.C 1

Exhibit5.11 BELL FOUNDATION DETAIL FOR AN 80 FOOT TOWER Month Kilowatt-hours Capacity Factor (Q) April i1,697 41 May 15,397 52 June 20,297 71 July 19,369 65 August 18,257 65 September 19,589 68 Oc her to 16,605 59 November 10,671 37 December 8,64 29

F:'sed on Actual Wind Velocity Distribution (10 meters AG,): 140,488 54

Based on Raleigh Distribution of Wind Velocity 128,371 49

Reference: Battelle Pacific Northwest Laboratories

Exhibit 5.12 40 kW, 60 Wkrtz Wind Turbine Performance at Ras Ghareb

31 APPENDIX A

Engineering Cost Estimate

A-i The engineering cost of a wind farm at Ras Charob is dependent on the Specific turbines instail-1 I, t:ho typo of tow,,r used , the s i:o of the foundation

requi oid, and !he Pxtent 4)1 civil work required for ac e roads) And interconnect.

The folIowin cost e';timat, i bas ed on average, cost s of a ron of similar

oqu i pme n t a;nd the fo I low i ., as umpt i o n s : I . Freight coS t fo r onoe *'O-foot shipping containpr from the U.S.A. to Eg.ypt is 53,Mor'). 'lrhirr, .nd tower snhipmnrent n-I i, no o:;e conta iner pe r sV'; tem.

b. Tower foindlat in.; recqire 50 cubic yards of concrete at $59 U.S. per cubic 'ord.