Ground MountedphotovoltaicpowerplantsDesignguidelines r1

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IEC 62738:2018 Ground-mounted photovoltaic power plants-Design

guidelines and recommendations
Presentation · February 2019

DOI: 10.13140/RG.2.2.34990.77124
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IEC 62738:2018 Ground-mounted
photovoltaic power plants – Design
Feb 2019
Presented by Samer A Zawaydeh, Msc, CRM®, REP™
@
Jordan Renewable Energy Pioneers
Samer A Zawaydeh Feb 2019 1

Eng. Samer A Zawaydeh, Msc, PMP, CRM, REP, AVS
Association of Energy Engineers
Assistant Director for International Membership
Development for Special Projects
Independent Engineer, providing Energy Efficiency, Renewable Energy, High Performance

Building, Contractual, Project Management and Value Engineering services to the
Construction and Energy Management industries
– Bachelor in Civil Engineering - Structures

– Masters in Structural Mechanics, USA
– Environmental and Energy Engineering Master Program
– Project Management Professional, PMP
– Associated Value Specialist, AVS
– King Abdullah II Award for Excellence, Mentor
– Carbon Reduction Manager, CRM®
– Renewable Energy Professional, REP
– Planning & Scheduling Professional , PSPC
– Cost Management Professional, CMPC
– Legend in Energy, 2012
– The Community Power Reporter, Middle East
• Membership
– Association of Energy Engineers AEE, Life Member
– Local and International Energy Associations
2
Table of Content
• PV array system configuration
• Safety issues
• Selection and erection of electrical equipment
• Acceptance
• Maintenance
• Marking and documentation
• Medium and high voltage a.c. systems
• Auxiliary power systems
• Communications systems

PV Power Plant
• Definition
– A grid-connected, ground-mounted system
comprising multiple PV arrays and interconnected
directly to a utility’s medium voltage or high
voltage grid.
• Additional criteria is that PV power plants are
– Restricted from access by non-qualified persons
– Continuously monitored for safety and
protection, either by on-site personnel or by
active remote monitoring.

PV array system configuration

Array Electrical Diagrams
• Multiple sub-array configurations
• Single array configuration

Multiple sub-array configurations
• Multiple parallel string case with array divided
into sub-arrays
• PV array example using a PCE with multiple
MPPT D.C. inputs
• PV array using a PCE with multiple D.C. inputs
internally connected to a common D.C. bus

Multiple sub-array configurations

PV array example using a PCE with
multiple MPPT D.C. inputs

PV array example using a PCE with
multiple MPPT D.C. inputs
Example (SMA Core 1 = 6MPPT)

PV array using a PCE with multiple D.C. inputs
internally connected to a common D.C. bus

Single Array Configuration

Energy storage in PV power plants
• Not addressed in this standard
Samer A Zawaydeh Feb 2019

https://www.adelaidenow.com.au/business/sa-business-journal/lyon-group-plans-to-build-the-worlds-biggest-solar-and-battery-project-in-roxby-downs-starting-next-year/news-13
story/bb7ca285f08c1f09ada69a8b527f1264
Array Physical Configurations
Fixed tilt arrays
Adjustable tilt arrays
Single Axis Tracking Arrays
Two-axis tracking arrays
Concentrating PV arrays
Central inverter configurations
String or module inverter configurations

Fixed Tilt Arrays
https://pvpmc.sandia.gov/modeling-steps/1-weather-design-inputs/array-orientation/fixed-tilt/

Adjustable Tilt Arrays
https://www.leelanausolar.com/Products.html
Single Axis Tracking Arrays
https://www.solarpowerworldonline.com/2015/05/array-technologies-launches-new-single-axis-tracking-system/

Two-axis tracking arrays
http://www.ee.co.za/article/solar-pv-tracking-systems-can-increase-output.html

Concentrating PV arrays

Central Inverter Configurations
https://www.google.com/search?q=Central+inverter+configurations&tbm=isch&tbs=rimg:CecEOXAsJbbUIjjOeL6VtDd-tF1Pgz8vJ9jEVm8acTyBCFBkvXxfYGI8GSUsaNeIK-
pGm_1ui0_1UiNLXlDj9otTmoCyoSCc54vpW0N360ESDCbCfChCwcKhIJXU-
DPy8n2MQRc2sJq4KFCNcqEglWbxpxPIEIUBEs2abmlRokCioSCWS9fF9gYjwZEcMyMYGN1z21KhIJJSxo14gr6kYR1sSGlmWfKawqEgmb-
6LT9SI0tREbkXNmuCCS2SoSCeUOP2i1OagLEfmSMn_111fzr&tbo=u&sa=X&ved=2ahUKEwj0yN20vvDeAhUEDOwKHZOeBTsQ9C96BAgBEBw&biw=1366&bih=577&dpr=1#imgrc=pxw5ux_Z_3d_C
M:

Central Inverter Configurations
Shams Maan

String or Module Inverter Configurations

Mechanical Design
• Mechanical loads on PV structures
• Wind
• Snow
• Thermal Expansion
• Flooding
• Seismic activity
• Corrosion
• Access

Mechanical loads on PV structures
• According to measured and documented site-

specific conditions
• Loading requirements for PV modules defined
in IEC 61215-2
• Local approving authorities

Jordan Engineers
Association
Projects:
Solar PV
Bore holes
Mandatory

Jordan Engineers Association Projects: Solar PV
Soil
Electrical
Resistivity
Mandatory

Standard Penetration Test (SPT) Soil Testing
This test method describes the procedure, generally known as

the Standard Penetration Test (SPT), for driving a split-barrel
sampler with a 140 lb [63.5 kg] hammer dropped 30 in. [750
mm] to obtain a soil sample for identification purposes, and
measure the resistance of the soil to penetration of the
standard 2 in. [50 mm] diameter sampler. The SPT "N" value is
the number of hammer blows required to drive the sampler
over the depth interval of to [0.15 to 0.45 m] of [0.45 m]
drive interval.

Standard Penetration Test (SPT) Soil Testing

Jordan Engineers Association



JEA – 100 hrs training course

Jordanian Loads and Weights Code
Wind Load Snow Load
(follow the code for details) (follow the code for details)

Jordanian Code
Loads Combinations

Bolt Torque Table

Steel vs Aluminum Strength

Wind
• Local codes governing wind-load calculations
for buildings may be either not suitable or not
adequate for PV arrays
• Site specific conditions
• Application-specific structural engineering
calculations
• Documented and approved by local approving
authorities

Wind failures
https://www.renewableenergyworld.com/articles/print/volume-18/issue-
4/features/solar/ensuring-your-solar-array-doesn-t-get-caught-in-the-wind.html
https://solarprofessional.com/articles/design-installation/designing-pv-systems-for-
environmental-extremes/page/0/1#.W_sbbjgzbIU

Snow
• Effects of snow
sliding
• Resulting lateral
Loads
• Frost Depth at site

Snow failure
https://solarprofessional.com/articles/design-installation/designing-pv-systems-for-environmental-extremes/page/0/1#.W_sbbjgzbIU

Thermal Expansion

https://www.propertycasualty360.com/2013/07/01/identifying-solar-panel-failures/?slreturn=20181025165200
Thermal Expansion
Depends on the thermal coefficient of the
material used.
• Mounting rack length
• Module frame separation
• Cable management
• Rigid mechanical connections of long linear
spans

Thermal Expansion Failure

https://www.propertycasualty360.com/2013/07/01/identifying-solar-panel-failures/?slreturn=20181025165200
Flooding
• Project sites are at risk of flooding,
• Height above the ground of modules,
combiner boxes, tracker motors, and other
electrical components should be considered.
• Soil Strength Changes
• Site Drainage
• Signs of Vegetation in open deserts indicates
water flooding
Flooding

https://www.solarpowerworldonline.com/2018/01/solar-industry-responding-increasing-intensity-natural-disasters/
Seismic Activity - Jordan
Samer A Zawaydeh Feb 2019 https://books.openedition.org/ifpo/4861

47
Extreme Weather Events
https://www.fema.gov/media-library-data/1535554011182-e061c2804fab7556ec848ffc091d6487/USVI-RA5RooftopSolarPanelAttachment_finalv3_508.pdf
Corrosion
• Salt content in water
• Corrosive chemicals in the local atmosphere such
as ammonia in agricultural areas
• Sulfates found in soils.
• Humidity
• Action: Testing of Soil, PH level, Levels of
Chemicals; Sulfate and Chlorate.
• Components: Sub soil, Super structure, cables,
cable trays, Air tight equipment

Corrosion Failures (examples)
https://www.google.com/imgres?imgurl=https%3A%2F%2Fwww.pv-magazine.com%2Fwp-content%2Fuploads%2F2018%2F07%2FIndiaPVrisks3crPIBerlin-
1200x800.jpg&imgrefurl=https%3A%2F%2Fwww.pv-magazine.com%2F2018%2F09%2F12%2Fensuring-quality-will-bring-reputation-prestige-to-indian-
pv%2F&docid=HnYRpg8K4krjkM&tbnid=jvGsQja-
mZmMlM%3A&vet=10ahUKEwiOhv61zfDeAhWFBiwKHQGPAtIQMwh1KCwwLA..i&w=1200&h=800&bih=577&biw=1366&q=rusted%20PV%20mounting%20structure&ved
=0ahUKEwiOhv61zfDeAhWFBiwKHQGPAtIQMwh1KCwwLA&iact=mrc&uact=8

Stainless Steel with Painted Steel

Stainless Steel with Galvanized Steel
https://www.mcfeelys.com/galvanic_corrosion

Access
• Emergency vehicles and local fire codes:
– dictate the maximum length of contiguous arrays
– minimum width of vehicle corridors in each direction.

Access
• Asphalted roads to inverter locations.
http://enviromena.com/casestudies/masdar-city-abu-dhabi-uae-and-quweira-jordan/
Foundation - Exposed

Foundation - Ramming
Sections Machines

Foundation - Ramming
Machine Bolts

Foundation
Concrete Foundations Ramming Bolts

Safety issues

Installation without Safety +
Damaging PV Modules

General
• PV arrays in power plants shall have no
restrictions on maximum voltage ratings other
than those imposed by the ratings of the
equipment employed.

Restricted access
• Restricted Access
• Site specific safety rules and procedures

Example: Occupational Safety and
Health Administration
https://www.osha.gov/
Restricted Access

Site specific safety rules and
procedures

Access to Components
http://ap-verlag.de/kommunale-energieversorgung-sonne-wind-wasser-co-effizient-gesteuert-durch-neue-leitwarte/42203/

Real-time monitoring from Berlin control
centre
http://www.sunwindenergy.com/photovoltaics/real-time-monitoring-berlin-control-centre

Protection against overcurrent
• DC over curent protection device
• Requirement for string overcurrent protection
• String overcurrent protection sizing
• PV sub-array and array overcurrent protection

Protection against effects of lightning
and overvoltage
• Lightning protection
• Protection against overvoltage

Lightning protection
• The extent of protection needed depends
highly on the level of lightning activity at the
project site.
• The lightning risk should be assessed during
the detailed design phase using IEC 62305-2.

• a) Equipotential bonding of array racking or tracker structures.
• b) Lightning/surge protection devices installed in the string or harness
combiner boxes.
• c) Lightning/surge protection devices installed on d.c. and a.c. side of inverters.
• d) MV surge protection at substations and feeder termination points.
• e) Building mounted air terminal and down conductors with ground rings for
walk-in enclosures, operations and maintenance (O&M) buildings, or other
facilities.
• .

Example
• Equipotential bonding of the array field components is
recommended to achieve an effective 20 m by 20 m mesh

Protection against overvoltage
• Surge Protection Device (SPD)
• Power Conversion Equipment (PCE)
• If the PV system is connected to other incoming

networks (such as telecommunication and signalling
services) SPDs shall also be required to protect
information technology equipment.
• Selection and application of SPDs should in general

follow the principles outlined in IEC 61643-32

Protection against fire
• Earth-fault protection
• Protection against arcing currents

• The Employer is responsible for developing a fire
protection program
– Providing access to fire fighting equipment at all time
– All fire fighting equipment shall be conveniently
located
– Periodic maintenance and inspection required
– Defective equipment shall be immediately replaced

•

•

•

Earth-fault protection
• Purpose of a ground-fault protection device
(GFPD) as part of a PV power system is to
reduce the risk of fire associated with a ground
fault. "If the ground fault is a short-circuit,"
https://www.google.com/search?q=PV+Earth-fault+protection&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiowrrI4YrfAhWoM-
wKHabjA68Q_AUIDigB&biw=1366&bih=577#imgrc=3LwPoISIDlBYxM:
Protection against Arcing currents
• Arcing currents are a dominant cause of fire
• Prevented by
– Quality installation practices,
– Properly torqued terminations
– Well installed and seated PV connectors
– Quality wire management (mechanical protection)
– Management of vegetation and rodent infestation.
• Not required but can be an effective part of PV
power plant and property protection
Protection against Arcing currents

7 Selection and erection of
electrical equipment

8 Acceptance

General
• Successful completion of inspections

• Commissioning tests
• Performance validation tests
Note: The recommendations in this IEC apply primarily to

the low voltage PV DC and AC sub-systems.

Intermittent Renewable Resources (Wind and PV) Distribution
Connection Code (DCC) At Medium Voltage (MV)
http://www.emrc.gov.jo/images/electric/rules
_renewable_energy.pdf

Intermittent Renewable Resources (IRR) Wind & PV
Transmission Interconnection Code (TIC)

Monitoring
• Solar resource, weather
• PV system performance should comply with the
requirements of IEC 61724-1.
• Large plants with multiple data logging stations
benefit from using GPS based-time stamps to
ensure that data is properly synchronized.
• When using custom weather stations to support
plant designs, it is recommended that wind
speed measurements be capable of capturing 3 s
averages to address wind gust design criteria.

Commissioning Tests
• Minimum, those included in the Category 1
test regime specified in IEC 62446-1.
• String I-V curve and thermal imaging tests
defined in the Category 2 test regime of IEC
62446-1

Preliminary Performance Acceptance
test
• Include the requirements of IEC 61724-2.
• Additional steps such as verification of
sample module flash test values according to
the module rated power and tolerance can be
considered.

Final Performance Acceptance Test
• Include the requirements of IEC TS 61724-
3:2016 Photovoltaic system performance -
Part 3: Energy evaluation method
• Additional steps such as verification of sample
module flash test values according to the
module rated power and tolerance can be
considered.

9 Maintenance

• Plant maintenance practices and procedures
follow the applicable requirements of future
IEC 62446-2.
• Photovoltaic (PV) systems – Requirements for

testing, documentation and maintenance –
Part 2: Grid connected systems – Maintenance
of PV systems

10 Marking and Labeling

Labeling

• Component labeling and identification shall
comply at a minimum with the requirements
of IEC 62446-1

Labeling of disconnection devices and
combiner boxes
• Marked with an identification name or number
according to the PV array wiring diagram.
• If the disconnecting device is located in a
combiner box, the switch may be identified by
the combiner box name and numbering.
• All switches shall have the ON and OFF positions
clearly indicated and further safety information
might be provided inside the enclosures.

Documentation
• Documentation of the PV power systems shall
comply at a minimum with the requirements
of IEC 62446-1.

Additional information
• Design and site condition parameters
• Applicable codes and standards for the specific location of the plant
• Other design related statutory requirements
• A bill of materials for all major power plant components identifying part
numbers, supplier, ratings, and certifications
• A recommended spare parts list
• Justification of design methods where standards or codes are not fully utilized,
specifically identifying where designs or equipment:
• Are not compliant with applicable standards and codes
• Are compliant with applicable standards and codes, with exceptions
• Are compliant with equivalent or alternate standards and codes
• Have no pre-existing basis in available standards and codes
• Have adequate engineering assessment in lieu of standards
• Have adequate field evaluation in lieu of factory certifications
• Particular installation procedures where applicable
• Array density, shading, D.C./A.C. ratio, earthing schemes, lightning protection,
AC. protection coordination
13 Communication Systems

SCADA
• Follow local utility requirements pertaining to
compatible protocols, required parameters,
and sampling. General communication
protocols should meet requirements set forth
in:
– IEC 61850
– IEC 60870-5-104

Local Requirements

Local Requirements

Data Sampling Speed Requirements
• High sampling rates (less than 30 s to 1 min) are not required.
• Higher speed sampling and polling for example 1 s, is helpful for
communication between the metered point of connection with the
utility and each of the inverters.
• Higher rate samples may be used for fault diagnosis in plants
interconnected to utility grids that are relatively unstable or
otherwise prone to voltage or frequency excursions.
• Polling speed of a centralized data system is affected by the large
number of inverters, so this should be considered.
• It is important to ensure time-stamp coordination for combined
measurements when multiple data sources are employed.
• Specialized metering instruments with SCADA system to record
high-rate data for specific utility fault, ride-through, or harmonics
measurements.

Inverters

Advantages of string inverters
• Simplification of D.C. protection such as for arcing and
earth-faults.
• PV array more tolerant to mismatch and shading
• Inverter consolidates more granular monitoring of strings
for performance assessment and location of faults.
• Increased redundancy.
• An extension to system size is very modular.
• Widens the range of inverters that may be available,
• Allowing flexibility in selecting string voltages currents
and power ratings for each subsection.

String Inverter Sizes
Example (Up to 175KW)

Example (Up to 150KW 1500V)


http://solar.huawei.com/au/products

Disadvantages of string inverters
• Increased A.C. wiring and protection.
• More complex control when using inverter
based features to meet grid-interface
requirements

Advantages of Central Inverters
• Simplified architecture of D.C. distribution
circuits throughout the arrays.
• Often a larger range of control options are
available with respect to the grid interface.
• Control of these inverters is centralized with
respect to the grid.

Central Inverters
Example 2300KVA

Central Inverters
Example 2750KVA

Central Inverters
Example 5400KVA
https://www.ingeteam.com/es-es/sectores/energia-fotovoltaica/p15_24_39/ingecon-sun-inverterstation-u.aspx
Disadvantages of Central Inverters
• Increased cost in D.C. wiring and protection
• Independently operating sections of the PV array
at their maximum power point (MPP) requires
extra hardware on the D.C. side.
• Mismatch between sections (e.g. caused by partial
shading) may therefore significantly reduce the
overall system output.
• Monitoring of subsections of the PV array has to be
done in separate D.C. monitoring equipment.
• Incremental changes are more difficult
• Less redundancy

Issues affecting inverter size
• Environmental conditions
– Max Temperature
– Min Temperature
• The important outputs of this analysis are:
– Maximum array output voltage
– Maximum and minimum MPPT voltage
– Maximum array power
– Maximum array current

Inverter Rating
• Inverter shall remain within the maximum voltage, current and power
ratings as specified by the manufacturer under all normal and
foreseeable abnormal environmental conditions.
• The inverter shall be able to maximum power point track over the
range of operating MPPT voltage of the array.
• Inverter efficiency and thermal considerations need to be taken into

account for the environment where the inverter is installed including
any enclosure requirements.
• The altitude impact on inverter rating needs to be considered (cooling

capacity and switching device voltage capabilities are reduced in the
thinner air).

• PVI-3.6-TL-OUTD-S and PVI-6000-TL-OUTD-S, which are part of the UNO
family of single-phase inverters that represent the most efficient solution
for the majority of rooftop installations
UNO family is a line of inverters for external use which are ideally suited to
resist extreme environmental conditions

Thank You
IEC 62738:2018 Ground-mounted

photovoltaic power plants – Design
Feb 2019
Presented by Samer A Zawaydeh, Msc, CRM®, REP™
Email: samer_zawaydeh@yahoo.com
Mobile: 962.78.839.9453

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IEC 62738:2018 Ground-mounted photovoltaic power plants-Design

Presentation · February 2019

Net Zero Energy Homes and Transportation View project

Energy Efficiency View project

The user has requested enhancement of the downloaded file.

Samer A Zawaydeh Feb 2019 1

Independent Engineer, providing Energy Efficiency, Renewable Energy, High Performance

– Bachelor in Civil Engineering - Structures

Samer A Zawaydeh Feb 2019 3

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• According to measured and documented site-

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This test method describes the procedure, generally known as

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