Transformers For Renewable Energy 2 TMC

TMC TRANSFORMERS FOR RENEWABLE ENERGY
This documentation must not be copied without our written permission and the
contents hereof must not be imparted to a third party nor be used for any INTERNAL REF. FP VERSION 1
unauthorized purpose. Contravention will result in prosecution. DATE 02.03.2011 PAGE 1
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Index
1. Availability of Energy sources

2. Research of New Energy Sources: why?
3. The most representative renewable Energy sources
4. TMC transformers for renewable Energy
5. TMC transformers for Wind Turbine (WTT)
6. TMC transformers for Photovoltaic parks (PPT)
7. IEC for Wind farms and Photovoltaic parks
8. Supplier’s requests for Wind farms and Photovoltaic parks
9. Manufacturing companies for Wind farms and Photovoltaic parks
10. Some photovoltaic Power Plants powered by TMC Transformers
11. Some Wind Farms powered by TMC Transformers
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1. Availability of Energy sources
The most used sources to obtain Energy in the Power plants are: Petrol, Gas and Coal.
Moreover, there is a little part of Energy produced by other types of Power plants like Hydroelectric,
Geothermic and Nuclear:
The problems of transformers installed in these types of Power plants are already known from many years.
Often Oil Transformers are used in Hydroelectric and Geothermic plants while in the Nuclear plants the
Cast Resin Transformers are preferred for security reasons.
2. Research of New Energy Sources: why?
Day after day the air pollution grows up, it is difficult and so expensive to eliminate the radioactive wastes .
The Hydroelectric and Geothermic Energies are not available everywhere, for this reason new solutions are
researched with clean energy, which initially can be expensive but in the future they will show benefits.
In the last years the most important renewable sources come from the wind and solar application.
3. The most representative renewable Energy sources
The development of renewable energy sources represents the most effective answer to the necessity for
reduce considerably the use of oil and other fossils responsible for the increase of the greenhouse effect
and for air pollution.
Here following some sources of clean Energy:
 Biomass: actually, it represents the most widespread resource. This is a process makes by-products like
the wood or waste of organic origin.
 Thermovalorization: it is a process that allows to raise the combustion temperatures of solid urban
waste generating the steam, than it pass through the turbine that creates energy.
In the thermovaloritazion fuel costs is nonexistent, so this energy source is a valid alternative to fossil
fuels that are expensive and non-renewable.
 Solar thermodynamic process: it is a process that brings the solar radiation into collectors that
concentrate the heat in tubes. Through the use of synthetic oils there is the production of steam that
moves a turbine for generate energy.
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 Geothermal energy: it is the heat stored under the top part of the earth crust. This heat is permanently
available regardless of weather conditions and the moment of day. It is a great and economical source
of energy; it’s classified as regenerative and provides generation of energy without emission.
Geothermal power plants use the heat stored in the earth to feed a generator of steam turbine.
Compared to Coal power plants, each megawatt installed in the geothermic power station can reduce
the CO2 emissions 6,500 tons per year. This is why some countries offer subsidies for their construction
or for the electrical power from geothermal plants.
 Energy Generation with Combined-Cycle Gas Steam: it is a power plant with a combined cycle that uses
the combination of gas turbine and steam turbine to generate electricity from an only fuel. In fact,
recovering the thermal energy of exhaust gases from the gas turbine in order to use them to generate
steam, the combined cycle can turn the fuel energy with interesting efficiency values.
 Fuel Cells: they are based on a controlled combustion reaction, in which the fuel is hydrogen (H2) and
the oxidizing agent is oxygen (O): the final product is the water (H2O). The electrode, the anode and the
cathode are immersed in an electrolyte that can be in different types (phosphoric acid, from fused
carbonic, from solid oxide ceramic, etc.). The supplied energy continues until the fuel cell is fed with the
anode fuel and with the cathode oxide. The two reagents do not come directly in contact between
them, but only through the electrolyte mediation. Completes plants are constituted, above cells, with a
system (reformer) for produce hydrogen, that is obtained from different types of available fuels (natural
gas, biogas, etc.). As well as the advantage to use fairly fuels, fuel cells offer other benefits, such as the
extreme variety of installable power (from some kW up to 100 MW) the minimum noise and excellent
energy efficiency. However, some technologic improvements are necessary, for transform fuel cells
more competitive than the traditional sources of energy.
 Photovoltaic (Solar Energy): the solar energy is the electrical energy produced using directly the energy
radiated by the sun, renewable source, towards the earth. In any time the sun send to the earth orbit
1367 WATTS per m². The earth is a sphere that rolls, the medium solar radiation is approximately 200
WATTS/m² at the European latitudes. Multiplying this average power per m² for the earth's surface
exposed at the sun, you can obtained an higher power of 50 million GW (1 GW-Gig watt- which is the
average power of a big power plant).
The quantity of solar energy that the earth receives is enormous: about 10,000 times higher than all the
energies used by the humanity. It’s necessary to take this energy from large areas in order to have
significant quantities but it is difficult to convert it into workable energy with acceptable efficiencies.
The photovoltaic electricity production is based on the enable to transform the solar radiation in
electricity through cells with disks of mono silicon or polycrystalline. This process was already known but
forbidding prices have limited the application on industrial scale. With straits which coming from doubts
of oil or gas supply and their increasing costs, many nations have developed more competitive systems
also with the state intervention always more marked (from small power for domestic use until industrial
powers of many KW or MW for solar energy parks).
The system has the following essential components:
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• solar panels
• chase systems of maximum sunshine
• inverters that convert the continue voltage into alternate voltage
• transformer coupling that transforms the inverter output voltage into the grid voltage; by networks to
400 V up to networks of distribution of energy up to 24 KV or 36 KV
• paralleling boxes of electrical net and fields
 Electricity with Wind Turbines

Originally, the wind energy developed as an alternative form of energy, then it has become a reliable
energy source and it is used on a large in scale and perfectly integrated in MIX energies, like oil and gas.
It is forecast that the wind energy will reach at least 10% of world energy consumption within 2020.
Up to 30 June 2010, more than 80.000 turbines have been installed in over than 75 countries in five
continents: Italy has 3500 turbines for a total of 4.000 megawatts.
Usually modern wind turbines use a rotor with three large blades which have a diameter between 40
and 80 meters, this to capture the wind and to extract energy from the largest possible volume of air.
The blades are adjustable in different angles in order to hack with various wind speeds, and both the
generator and the blades can be turned to face the change of wind direction.
Wind turbines are mounted on 40 - 100 meters high in order to catch stronger wind flows.
Generally wind turbines produce electricity when winds are speed 15 km/h or more. For safety reasons
they have to be disconnected when the wind exceed 90-110 km/h.
Blades are connected through a shaft to a voltage generator that transmits the generated voltage from
480 to 690 V to a WTT, which is normally placed on the base of the structure that supports the wind
turbine.
The transformer must be small, especially in width, for an easy access to the same base. The
transformer is used to "step up" the voltage, so the electricity can be delivered through transmission
and distribution lines to domestic users.
4. TMC transformers for renewable Energy
TMC produces dry-type transformers and reactors with epoxy resin cast windings
that are suitable to work on service in special environment (tropical climate
55°c). The power range is between 160 KVA up to 3150 kVA primary and
secondary Voltages find their limit to 36kv. Around 50% of production is
addressed to special uses:
• Photovoltaic parks according to IEC 60076/16
• Wind turbines according to the draft IEC c947/2006
During the years TMC has performed and perfected transformers with characteristics that are adapted for
installation of renewable energy, participating in the normative formulation for this type of plants. For
example, we took part in the WG31 for the drafting of the wind energy standard (IEC 60076-16).
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Thanks to an internal laboratory with equipment of last generation (anechoic chamber, refrigerators for
low-temperature tests, last generation for impulse generator with 14-bit
revelation, total area shielding and input filters in order to remove the
electrical faults, …..) and a research/development department that is
always active and competent, we have innovative solutions in the
electrical, mechanical and thermal field. These developments have
qualified a new system for heat disposal for LV windings that allows
containing their sizes. This system is helpful for wind power, where
spaces are limited.
As per the photovoltaic, new system windings have been found which allow realizing multi primary
transformers.
5. TMC transformers for Wind Turbine (WTT)
The WTT power transformer is the heart of the energy generation. The
original plane of transformer can have deep effects implications on the
future profitability of wind farms, for this reason the transformers
planning and construction used in wind farms - including Wind Turbine
Step-Up (WTT) Transformers - assume critical importance.
Although wind technology has shown some improvements during the
last few years, there are main problems of concept, planning and
control. If these questions are not properly addressed at the right time, they may cause in the system some
significant disturbances, especially when interconnected with the existing power grid. A Wind Turbine
Transformer (WTT) carries out a fundamental role in the conversion of the generator output to the
interconnected power grid of the end users. Output voltages of wind turbine are from 480 volts to 690 volts.
This output voltage is transferred to the WTT and transformed into a collector voltage of 12 kV up to 36 kV.
Today WTT transformers have the following aspects:
 Load variation
 Resistance to harmonics and non-sinusoidal currents are generated from electronics control and
generators
 Sizing without protection for over-voltage, under-voltage or over-loading
 Necessity to tolerate temporary and fault events
 Resistance to mechanical vibration
For these reasons Wind Turbine Transformers cannot be considered as standard transformers (distribution
transformers or generator step-up transformer).
5.1 The necessity for special design
Wind resources are often located in remote areas, far from existing plants and subject to wind variation.
These factors transform the wind in an uncertain energy resource that can cause power waver up to 25%.
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About 10% of the time, wind may produce a time power of 5-20%. This variability may affect negatively
on the power availability.
Usually conventional distribution transformers and step-up transformers have a consumption oriented to
the most constant. The thermal stress on insulation is higher. WTT transforms don't suffer of these
problems, but the variable load causes other problems, such as:
 Core Losses: it can become a significant economic factor for not much loaded
transformers. Operational scenarios with an average load of 30 -35% required the use of
formulas revaluation costs. Losses capitalization (for a considerable period) may affect the
transformer size and the purchase price but it can reduce the cost in the period of use.
 Thermal Cycling Varying: they can put repeated thermal stress on the winding in case of
uncontrolled overloaded and also on the structure creating hot-spot and partial discharges:
they can damage the insulation. The distribution transformer and power generator step -up
transformer designs cannot be used in these conditions.
5.2 WTT Transformers: design and construction
WTT transformers shall be built started from the following considerations:

 Core has to be with steps
 Windings have to be more strong and isolated
 Strong lock structure
 Protection measures that will prevent hot spots and partial discharges
No load losses shall be lower than those assigned to distribution transformers. All these points can
contribute to extend the life of transformer and to improve the reliability. More than rectifier
transformers, the TMC WTT has to be designed with high harmonics, highly variable loads and with
electrostatic shield to prevent the transfer of harmonic frequencies between the primary and
secondary windings. Conventional products can’t include all these characteristics and design
considerations.
Moreover, WTT are connected in line with solid state controls in order to limit the inrush currents. This is
different from the typical step-up transformers which have to be designed to withstand high surge
currents which cause the core saturation.
While these controls aid the starting magnetization, they increase voltage harmonic frequencies that,
when coupled with the load non-sinusoidal wave forms, they take in consideration the temperature rise.
When a rectifier/chopper system is used, the WTT have to be designed for harmonics similar to rectifier
transformers, taking into consideration an additional loading.
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5.3 WTT Transformers: Estimation of energetic losses
The energy produced by wind turbines is often checked on the LV side, this is a mistake because the
transformer efficiency is not considered. This efficiency is much lower than the higher losses (load and no-
load losses)
As you can see in the following pictures, the energy measured in the meter position is equal to Ewind, while
the actual energy delivered to the grid is equal to Edelivered.
Their differences are the losses caused by the transformer (cables have to be included). To calculate the
delivered electricity it’s necessary to make an estimate of transformer losses (load and no-load losses). The
measurement on the LV side shows us the total electricity produced by the wind turbine during one year.
These values are not sufficient to make an estimation of losses caused by the transformer: in fact, to
calculate the losses of the transformer it’s necessary to know the distribution of wind speed during the year.
Together with the turbine P-v curve, it’s possible to do an estimate of the electricity profile of the wind
turbine as indicated in the figure below (750 kW wind turbine).
Based on these figures, the total annual electricity produced by the wind turbine (which must be equal to
the measured energy) is about 1.850.000 kWh (load factor about 28%). If it is used a 1.000 kVA distribution
transformer (no load losses: 1.100 W - load losses: 9.500 W), it’s possible to calculate the losses due to the
transformer.
Until the transformer is connected to the grid (even at low wind speeds) it will not always have load losses
equal to 1.100 W * 8.760 h = 9.636 kWh, while mixing levels given above it is possible to make a load
distribution over the year.
With this distribution it is possible to calculate the total amount of load losses caused by the transformer:
in this case the annual load losses are estimated at 8.279 kWh, the total annual losses of the transformer
equal 17.915 kWh; this is about 0,97% of the electricity produced by the wind turbine. The electricity
delivered to the grid is about 1% less than measured at the LV side.
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6. Tmc Transformers for photovoltaic parks (PPT)
As the wind power, transformers for photovoltaic parks PPT are the
heart of energy transformation produced by photovoltaic cells. This
energy is transformed from DC to AC in order to be more easily
transferred (voltage from 200 – 700 V to 12-24-36kv). The transformers
for photovoltaic are not subject to the problems that affect the wind
turbine transformer. The installations are generally in not aggressive
environments, both for climatic condition and for mechanical stresses.
The optimization of photovoltaic parks depends from other
parameters which make them not easy to design. To reduce the
costs, losses and the same cost of transformer, executions are
carried out with 2 or 3 primary windings. These windings are
powered by inverters, which are connected to the various cells of
the Photovoltaic Park.
The harmonic pollution, due to the inverter, has usually low
importance. The efficiency of PPT are usually higher than
distribution transformers.
The execution of double primary voltage is usually made with
coupling factor of winding next to one, in case of Triple primary, it is
considered a coupling factor very low. The reasons for the two
choices are constructive, because there is any necessity, as for
traction transformers, to have absolutely coupled windings (k=1).
Advantages of coupled windings are the low no-load losses for this type of construction compared to the
decoupled type. The importance of the low level of no-load losses is felt in photovoltaic even more than in
wind power. Some manufacturers require a transformer efficiency of 99% at fuel load.
7. IEC for Wind farms and Photovoltaic parks
 IEC 60076-16 Winds turbines_V1 Transformers for wind turbines

 IEC 60076-1/3/5/10 Standards for transformers test and construction
 IEC 60076-11 dry – type power transformers
 Technical Help 82-25 for the design, installation and the verification of plants Fv in parallel to the
grid of MV and LV;
 IEC en 50380: data sheets and data plate modules Fv;
 IEC 600364-8 edition (section 712): Solar Photovoltaic (PV) power
 en 50461: solar cells-data sheets and product data for the crystalline silicon solar cells;
 CEI EN 60904: measure feature I-V/requirements/measurement principles;
 IEC en 61215: status of the project and type approval for modules in crystalline silicon;
 IEC en 61646: status of the project and type approval for modules thin film
 IEC en 62305: lightning protection;
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8. Supplier’s requests for Wind farms and Photovoltaic parks
In many cases the safety, quality criterion and rules are rejected by plants customers/designers and final
customers both for the ignorance of technical problems connected with the use and with the aim to
compete more.
A correct comprehension of security and a correct economy should make each partner more careful “the
quality is a self-paid method”.
Moreover, the energy conservation should be a common objective, this for minimize tragic effects of
atmosphere overheating that will see involved our successors.
Not always the final user is the same that acquires all equipments that compose the production plants of
renewable energy: this is the reason why the save sensibility (capitalized losses in the years) that we would
have acquiring a component (TMC PPT or WTT) of higher quality and productivity, it’s not always take into
consideration.
As per TMC policy for environments and products quality, when possible, we try to take the awareness way.
9. Manufacturing companies for Wind farms and Photovoltaic parks
9.1 Some manufacturing Company involved in the production or assembly of wind turbine
Farms
Siemens, ABB, Vestas, Super wind, Celme, Fuhlaender, Vergnet, Voith, Enercon, Gamesa, UOU, Nordex, EU
Energy, Soutwest indpower, Bornay, Magasol, Northern, Enertech, Torres ….
9.2 Some manufacturing Company involved in the production or assembly of Photovoltaic

Parks
ABB,Siemens, Conergy, Deca, Ecojoule, Fase, HT, IBC Solar, Ideal Energy, Novatech, Schuco, Sotevo, Tierre
Electric, Wagner, Solar Energy (ISES), Seia…
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10. Some photovoltaic Power Plants powered by TMC Transformers
Year Projects KVA Hv/Lv Q.ty Destination
2008 Photovoltaic Power Plants - Barcelona 400 25/0,42 9 Spain

2008 New solar silicon plant ii - Ppuertollano-ciudad real 3150 20/0,42 19 Spain
2009 Casella Photovoltaic Power Station - Casella (GE) 1250 15/0,3 2 Italy
2010 Avancis, Torgau 2000/2800 20/0,4 7 Germany
2010 Isola della Scala - VR 1250 10-20/0,275 1 Italy
2008 Photovoltaic Power Plants - Barcelona 400 25/0,42 9 Spain
2010 Huesca Photovoltaic Power Plants 160 20/0,42 1 Spain
2010 Huesca Photovoltaic Power Plants 160 25/0,42 1 Spain
2010 Lecce Photovoltaic Power Plants 1250 20/0,220/0,220 1 Spain
2010 Millenial Fair - Gonzaga (MM) 800 15/0,4 1 Italy
2008 Puertollano Photovoltaic Park - Ciudad Real 3150 20/0,42 19 Spain

2010 Isola della Scala - VR 1250 10-20/0,275 1 Italy
2010 Photovoltaic Power Stations - Puglia 250 20/0,4 2 Italy
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11. Some Wind Farms powered by TMC Transformers
Year Projects KVA Hv/Lv Q.ty Destination

2006 Alrota Wind Farm - Lisboa 2080 10/0,69/0,4 2 Spain
2006 Arbo Wind Farm - Galicia 2080 20/0,69/0,394 11 France
2008 Arteixo Wind Farm - Corunna 2350 15-20/0,69/0,4 1 Spain
2008 Concejiles Wind Farm - Nava de Béjar, Salamanca 2080 20/0,69/0,4 7 Spain
2005 Coruxeiras Wind Farm - Galicia (Lugo) 2080 20/0,69/0,394 31 Spain
2005 Coruxeiras Wind Farm - Muras (Lugo) 2080 20/0,69/0,394 23 Spain
2008 Cruz de Carrutero Wind Farm - Valladolid 2080 30/0.69/0,4 25 Spain
2004 Faro Farelo Wind Farm - Chantada (Lugo) 2080 30/0.69/0,4 82 Spain
2005 Fiouco Wind Farm - Galicia (Lugo) 2080 20/0,69/0,394 4 Spain
2008 Fuente Salada Wind Farm - Valladolid 2080 30/0.69/0,4 29 Spain
2005 Gavilanes Wind Farm - Murcia 1000 20/0,69 6 Spain
2005 Grijota Wind Farm - Palencia 1000 20/0,69 27 Spain
2006 Loma Viso Experimental Wind Farm - Albacete 2350 20/0,69/0,4 1 Spain
2006 Longchamps Wind Farm - Fienvilliers 2080 15/0,69/0,4 5 Spain
2006 Los almendros i Wind Farm - Murcia 2080 20/0,69/0,394 12 Spain
2008 Los Collados Wind Farm - Valladolid 2080 30/0.69/0,4 7 Spain
2007 Lucito (CB) and Melissa (KR) Wind Farms 2350 30/0,69/0,383 40 Italy
2008 Melissa Wind Farm - Melissa (KR) 2350 30/0,69/0,383 4 Italy
2006 Pebema Wind Farm - Ponferrada (Leon) 2080 33/0.69/0,4 65 Spain
2007 Pehimo Wind Farm - Santa Eufemia del Barco (Zamora) 2080 30/0.69/0,4 50 Spain
2006 Ramacca Wind Farm - Ramacca (CT) 2080 20/0,69/0,394 47 Spain
2006 Sao Joao Wind Farm - Lagos 2080 20/0,69/0,394 13 Portugal
2006 Sella di Conza Wind Farm - Castelnuovo di Conza (SA) 2080 20/0,69/0,394 6 Spain
2009 Serra Voltorera Wind Farm - Tarragona 2080 25/0.69/0,4 10 Spain
2006 Somolinos Wind Farm - Guadalajara 1000 20/0,69 12 Spain
2009 Vallée du moulin Wind Farm - Toulouse 160 20/0,4 5 France
2008 Veciana Wind Farm - Barcelona 2080 30/0.69/0,4 18 Spain
2008 Vieux moulin Wind Farm - Hautevesnes 160 20/0,4 6 France
2009 Windkraftanlage - Emmerich 1600 10/0,69 1 Germany

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TMC TRANSFORMERS FOR RENEWABLE ENERGY

1. Availability of Energy sources

1. Availability of Energy sources

2. Research of New Energy Sources: why?

3. The most representative renewable Energy sources

 Electricity with Wind Turbines

4. TMC transformers for renewable Energy

5. TMC transformers for Wind Turbine (WTT)

5.1 The necessity for special design

5.2 WTT Transformers: design and construction

WTT transformers shall be built started from the following considerations:

5.3 WTT Transformers: Estimation of energetic losses

6. Tmc Transformers for photovoltaic parks (PPT)

7. IEC for Wind farms and Photovoltaic parks

 IEC 60076-16 Winds turbines_V1 Transformers for wind turbines

8. Supplier’s requests for Wind farms and Photovoltaic parks

9. Manufacturing companies for Wind farms and Photovoltaic parks

9.2 Some manufacturing Company involved in the production or assembly of Photovoltaic

10. Some photovoltaic Power Plants powered by TMC Transformers

Year Projects KVA Hv/Lv Q.ty Destination

2008 Photovoltaic Power Plants - Barcelona 400 25/0,42 9 Spain

2010 Avancis, Torgau 2000/2800 20/0,4 7 Germany

11. Some Wind Farms powered by TMC Transformers

Year Projects KVA Hv/Lv Q.ty Destination

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