SC EGNATIA ROM SRL | JULY 2014

Technical Survey

Project: THIN FILM PHOTOVOLTAIC 4 X 1 MW

POWER PLANTS
Location: NUCI village, ILFOV county, Romania

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1. INTRODUCTION
1.1. Plant Description
The following survey is held for a 1 MW solar plant to be built in Nuci village, Ilfov county,
Romania. The project is one of 4 identical projects to be constructed in the same area. The
survey will study a solution with 46 Wp thin film solar panels and SMA central inverters. The
photovoltaic panels will be mounted in an area of 194 000 sqm. All the structures will be installed
within a perimeter of minimum 5 m inside the border of each area, in order to avoid shadows
from the fence and to comply with local regulations.
1.2. Plant Location
The 1 MW plants are located in one compact area, NE of Nuci village, accessible from road
101D (WGS coordinates: 4443'58.19" N, 2617'16.07" E). .

Fig. 1 Plant location

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1.3. Implementation stages

The construction of this project will be carried out following the stages below:
1. Site organisation

Installation of materials container

Installation of office container

2. Earthworks-Civil works

Plot leveling (if required)

Topographic plot definition
Topographic solar park area definition
Installation of mounting systems foundation (steel pile foundation)
Cable routing

3. Mechanical Equipment

Fixed mounting system

Fencing (NATO type)
Lighting system
Transformer LV/MV
Security and Surveillance System

4. Electrical Equipment

PV modules
Inverters
Equipment connection and installation
CCTV system

4. Connection with the grid Operational test period*

5. End of test period- Final connection with the grid*

* The grid connection technical solution and grid connection approval (ATR) are not yet arranged

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2. LAYOUT STUDY
The scope of the layout study is to determine the best position of the mounting system and
the PV modules in order to improve performance by minimizing the inevitable losses that occur in
every solar park due to:

Shading from natural obstacles

Shading from project elements and structures
Losses from energy conversion (DC-AC)
Cable losses

A layout proposal has been issued by the customer and will be taken into account for the
technical and commercial solution. Upon this layout, a cabling diagram was constructed for each
project.
Each of the projects will be structured following the below guidelines:

Minimum distance from fence: 5.00m

Mounting system 2 pile, 3 panels portrait
Mounting system inclination: 20
Installation of 21730 PV panels, 46 Wp,
Installation of 1 MV substation, 1250 kVA
Installation of 2 central inverters from SMA, type 500 CP XT
Installation of 18 string combiner boxes
Axial distance between mounting systems: 7.85m

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Fig. 2 Site Layout

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3. EARTHWORKS CIVIL WORKS

3.1 Marking of Site limits
Before the projects startup, the limits of the site will be clearly defined by a topographer in
order all the necessary works to take place inside these boundaries.
3.2 Earthworks
The earthworks inside the site will be limited to the removal of high vegetation and trees in
order to facilitate the marking of the foundation beams. Also, potential terrain leveling for the
formation of temporary roads inside the park may be required in order to facilitate the access of
equipment to its suitable installation positions. Also, the large concrete constructions present on
site will be demolished and carried away, if necessary.
3.3 Topographic works
The topographical works will be conducted by a certified topographic engineer with
suitable electronic equipment (GPS), in order to achieve the best precision of the mounting
systems axial distances and orientation. The engineer will mark the exact location of each
foundation beam, according to the layout study in order to proceed with the foundation and
installation of the mounting system.
The topographic works consist of:

Marking the limits of each site according to title deeds.

Marking the fencing
Marking the east-west limits of each table
Marking the exact places of all the foundation beams according to the study and ensuring
the specified distances between them
Marking of cable trenches in relation to the foundation beams

By the end of the topographical works, in the site there will be differently colored poles that
will define the exact location of each element and will facilitate the next implementation stages.
3.4 Substations foundations
According to the specifications of the substation, for each cabin a 1 m deep foundation will
be dug, which will be flled with a 300 mm layer of compacted ballast and a 100 mm layer of
compacted sand. Above these layers, will be installed the substation tub, 600 mm high (the
enclosure that gathers all the cables entering the substation - LV/MV).

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Fig. 3 Substation foundation

3.5 Cable and Grounding Ditches
Both DC and AC circuits of the park are to be built by means of underground electrical line, in
ditches that are designed in such a way that cable energy losses and costs are minimum. Also,
the grounding of the PV plant is made with steel tape buried in ditches. After the completion of
the works the ditches are covered according to normative with sand, soil, signaling tape and the
ground surface is restored and compacted. The digging works will be mechanized, done with
excavators, as follows:

M-shaped ditch excavation 0.8 m / 0.6 m

10 cm sand layer
Installation of cables at 2 x diameters distance
Fill up with sand for 10 cm above cables
Signalization tape
Installation of 120 tube with guide
Fill with excavation products
Ground compacting
Fig. 4 Cable Ditch

For the cable routing will be installed cavidotto tubes, 120 with preinstalled steel guide,
inside the ditches. These tube are a backup solution in case of cable failure for any reason in the
future. Under each inverter or panel, as well as at cross points with other routes, water protected
concrete manholes or shafts 0.4x0.40x0.80m, with an iron cover will be installed,. These shafts
will be bottomless in order to drain rain water and will have metal grid to prevent pest infiltration.
The tube entrance in the shaft will be secured with polyurethane foam.
Grounding ditches will be dug at a 0.4m depth, forming a matrix around the PV panels area,
so that every row of the mounting system will be connected to earth.

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3.6 Installation of mounting systems foundation poles

Before startup, a detailed geotechnical study will be conducted. The study will combine the
geological study along with pull out tests and compression tests in order to determine the suitable
length of the foundation beams, their suitable axial distance and the suitable foundation method
for each project, according to soil quality (piles ramming or piles and concrete). Prior to this
study, the offer will be done according with general data available for the exact area of the
project.
Poles installation is one of the more
critical tasks during the implementation of
the project and their installation will be in
strict accordance with the marks defined by
the topographer engineer. The foundation
poles consist of hot deep galvanized steel
with a minimum Zinc layer of 80m in
compliance with EN 1461 and the chemical
consistency of the soil and with 10 year long
anticorrosion guarantee.
The beams will be installed according
to the pre-specified marks with the use of
special installation equipment (ramming
machines), as seen in the picture.
Fig. 5 Poles ramming
The installation depth along with the beam axial distance will be determined after the
conduction of the geotechnical study. The PV mounting system will be supported on the
foundation beam and its assembly will be described further on.
3.7 Fence foundation
During this stage, the fence foundation will be built. Each pole of the fence will have a
separate concrete foundation and the ditch for the fence foundation will be dug on the exact
perimeter of each parcel, after a detailed marking done by the topographer. The concrete
foundation of the fence will be 20 cm wide x 40 cm deep.
3.8 Entrance ramp

A concrete ramp in the entrance of the park will be constructed in order to facilitate the
vehicle entrance on site. The ramp will have dimensions of 4.00x3.00x0.1m and will be made of
reinforced concrete C16/20. In case there is a need for a drainage system, a suitable pipe will be
embedded in the ramp.

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4. GROUNDING AND LIGHTNING PROTECTION SYSTEM

The final grounding and lightning protection system will be determined in respect of the
results of the grounding and lightning protection studies that will be conducted on site from
specialized teams and according to the norms of international standards and local legislation.
The direct grounding system of the project will consist of:
Hot deep galvanized steel beams
Grounding tape 30x3 St/Zn
Hot deep galvanized steel electrodes 20/1500
Conductors 1x10 mm2 (final dimensions pending results of studies)
4.1 Protection grounding
The purpose of the protection grounding is to eliminate the possibility of any electric
dynamic situation with any conductive surface that humans can get in touch with. By creating a
system with all its surfaces connected in a grounding kit, accident risks are eliminated. The
foundation poles of the mounting system will be installed at least 1.50m inside the ground thus
providing an excellent grounding system that protects all the parts of the mounting system.
Moreover, all the foundation poles will be connected to the grounding tape network.
Grounding tape 30x3 mm will be installed in a grid at a 40cm depth and will be connected
to the mounting structure in order to create a network that will provide grounding and protection
from electric shocks. The PV modules will be equivalent connected with each other and in both
ends of each row with the mounting system, through 1x6 sqmm conductors. The transformer will
be grounded through an inside Faraday cage and through an outside ring of grounding tape 30x3
placed at its perimeter that will have 20x1500mm electrodes in each corner and the grounding
network of the park will be connected with the transformers grounding ring. Through the installed
grounding systems the total park grounding should be below 1 Ohm.
4.2 Lightning protection from indirect hits (AC)
Inside the park and more specifically inside the transformer and the junction boxes, in
order to protect the equipment from shock overvoltage that could occur due to thunder hits on the
grid, a system of shock overvoltage by Raycap or a similar firm will be installed.Rayvoss
system is based on Strikesorb technology and can secure total protection from shock
overvoltages. This system is widely used in Telecoms, automations, defense, hospitals, energy
plants and other important E/M plants for protection of critical electric elements.
4.3 Lightning protection from hits (DC-passive system)
In order to minimize the possibility of overvoltage on the edges of the strings, all the DC
cables (+.-) will follow the same route in order to minimize the loop surface and therefore to
minimize induction current that can be caused due to electromagnetic distortions in the
atmosphere.
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5. METALLIC STRUCTURES
5.1 Fixed mounting system
The fixed mounting system consists of a double pile foundation mounting system that can
be adjusted in areas with abnormalities and significant inclinations. The mounting system will
respect Eurocode guidelines (EC1, EC3, EC7, EC9) and it will be statically calculated according
to Romanian legislation. The foundation beams consist of hot deep galvanized steel sections and
the main supporting system consist of aluminum sections on which the PV modules will be
placed.
The use of an aluminum structure offers a lot of advantages, compared to other types of
structures:
Reduced weight, which simplifies transportation and handling issues
Practically unlimited life span
Minimum maintenance costs (the oxide layer formed on the aluminum structure protects it
against corrosion)
Modular installation
Best weight/durability ratio

Fig. 6 Example of two-pile, thin film panel structure

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The assembly of the base is made upon the already installed ground beams. These beams
are installed in the ground with a depth, according to the results of the geotechnical study . The
connection of the aluminum structure on the ground beams is made with the hot deep galvanized
screws. The grounding of the aluminum structure is achieved through the beams that are injected
approximately 1.5 m in the ground. In this way each table is connected in an isodynamic way and
grounding is made directly. On the horizontal beams will be installed special rings that will sustain
the frames clippers. The rings will bear insulation material that will prevent direct contact of
aluminum frames with the bases aluminum, and therefore electrochemical corrosion in the future.
5.2 Fence
The preparation of the fence will follow the end off all earthworks. It will cover the length of
the perimeter of each site and will reach a 2.50m height. It will consist of 48 fence poles that will
be installed at 2.50m distance, metallic mesh 50x50 of 2.2mm thickness and 3 rows of barbed
wire on top of the fence.
The gate will have a 5.00m width in order to allow the easy access of vehicles and trucks
on site and will have of barbed wire on top in accordance with the rest of the fence. It will be
installed on the concrete ramp that will be constructed on each site. A 1 m wide pedestrian gate
will also be installed.

Fig. 7 Solar Park with fence (heavy duty fence with V poles and mesh on top)
5.3 Security system poles
Around the perimeter of each parcel and near each substation 6 m poles will be installed,
at a distance of 100 m away from each other. Video cameras and anti-breach infrared modules
will be installed on these poles.

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6. ELECTRICAL EQUIPMENT
6.1 PV modules
For the energy production thin film panels will be used. The proposal taken into
consideration for the plant is the use of 46 Wp type panels.
The panels will be installed in the active surface of the base. The installation will be made
with the use of special clip-holders, made by the same producer as the metallic structure, with
EPDM rubber protection in order to secure total fitting of the elements and compatibility with thin
film panels. The installation of the panels will take place according to their technical specification
and characteristics. A sort-out procedure is possible, by selecting and separating the modules,
according to the nominal current lmpp, by line up number. Afterwards, depending on the panel
type will be selected strings of panels with similar voltage output. In this way is maximized the
panel strings performance, avoiding losses due to panels mismatch.
All panels will be isodynamicaly connected with cable 7V-K 1x6mm2 and connected
with the grounding system. In order to minimize the possibility of induction overvoltage at the
end of the strings, all DC cables will lead through the same route in order to minimize the loop
surface they are included.
6.2 Inverters
The conversion of DC power to AC, in order to be injected to the grid, will be made with
central inverters, type SMA 500 CP XT.
The transformation of DC power to AC, in order to be injected to the grid, will be made through
inverters of SMA type CP. The specific inverters are chosen because of:

High performance reaching 98,5% under normal conditions, which is minimum losses
through transformation.
Flexible construction (outdoor).
Cost effective solution.

The inverter CP type can be used outdoors without any further supportive works, like
shelters or others and can easily be transported and is plug & play architecture solution. These
inverters assisted by Opticool system, can operate on Nominal performance even in environment
temperatures up to 50 C.

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Fig. 8 SMA 500CP XT type inverter

Due to highly integrated features of network management the inverters can cover existing
or future needs. The most important feature though is the smart power management that can
give 10% more power from the nominal 500 kVA, reaching 550 kVA, in environment
temperatures up to 25C. The inverters will sum up a total installed power of 1 MW. Taking into
consideration fixed panels position and the losses from the cabling and potential string
mismatches the inverters are fed constantly with the maximum power, making their production as
efficient possible and cost effective. Each inverter will be equipped with an add-on
communication kit RS485, in order to calibrate perfectly the inverter operation and send / process
data, to SMA server for the tele-monitoring system.
Features:
Maximum performance ratio 98.5 %
With the current error tracking system OptiTrac-MPP, is achieved the best performance
Effective cooling system OptiCool
Short circuit supervision insulation supervision
Power breaker C- DC
Overvoltage dispenser (AC,DC)
Outdoor
Protection class IP65
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Fig. 9 SMA 500CP XT efficiency curve

6.3 String combiner boards

In order to connect the modules strings to the DC inputs of the inverter, 18 string combiner boxes
will be installed. The inverter has 9 inputs on the DC side, so we will have 120 or 121 strings on
each input of the inverter. In order to achieve this, 3 or 4 strings will be connected in parallel,
using T shaped MC 4 connectors.

Fig. 10 Distribution board installation on the support system

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Fig. 11 Block diagram of 1 MW

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6.4 Substations
The LV/MV transformation is achieved for each park with a 1250 kVA, 0.31/20 kV
transformer with 2 low voltage coils. The transformers will be mounted inside precast concrete
enclosures, having 3 compartments: low voltage, transformer and medium voltage.
Inside the low voltage room of each substation will be installed the LV board, through
which the inverters are connected to the transformer. Here will also be installed the monitoring
system rack and data logger. Each circuit will be protected from over current with a 1000 A
contactor. The transformer room will be equipped with special fans in order to ensure optimal
cooling. The MV compartment is equipped with MV cells that ensure protection and compliance
with technical normatives:

Transformer cell with fuses

Separator cell
Switch cell with protection relay
UPS with minimum 8 hours of autonomy
Auxiliary transformer
Internal services board

The ventilation of each MV kiosk shall be done with forced ventilation through wind flows
and gravity flaps. All input cabling will be done through special cable entries on the bottom of the
shelter (substation tub) and covered with polyurethane foam to prevent water infiltration. Internal
cabling shall be done with properly dimensioned metal grade. Cabling between the 2
compartments shall be made with horizontal metal grade of sufficient dimension to host
corresponding amount of cabling. All equipment will be fixed on the floor with special anchor
bolts. 10cm distance between equipment and shelter wall shall be left for clearance. All
equipment shall be grounded to internal copper bus bar. All output cabling shall be done through
floor with proper opening that shall prevent dangerous cable bend radius and will protect cabling
from rodents.
Transformer characteristics:
POWER (KVA)
Type
TRANSFORMER TYPE
Ambient temperature
Primary voltage
Primary current
No load secondary voltage
No load losses
Load losses at 75C
Impedance voltage

1250
SEA TTO-4R2
Hermetic
-25C +40C
310 V
1804 A
20000 V
1350 W
13500 W
6%

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6.5 Power Plant Checking

Before and after the operation of the plant the following tests will take place by suitably
accredited personnel:

Grounding measurements
Grounding resistance < 1 Ohm
Cable Riso > 1000 MOhm
Inclination check for the bases
Pull out and horizontal testing in foundation piles
Zinc layer thickness measurement
Bolt tightening torque for mounting structure and for electric connections
Isodynamic connection check with multimeter
Cable checking on site
I-V of Isc testing in strings
Polarity
Input voltage for inverters < 700V
Polarity on AC cables
Quality control with thermal (max =10C)
Panels
Strings connections
Inverters connections
Board connections
Substation testing
Operation instruments and relays
Parameters for substation on Grid connection

6.6 System Standards

All electromechanical works will comply with the following Romanian Standards and
Normatives:
NTE 002/03/00:
NTE 005/06/00:

NTE 007/08/00:

Normative For Electrical Plants Protective Systems Tryouts And

Measurements
Normative Regarding Calculus Elements And Methods Of Electrical
Installations Functioning
Normative For Cable Electrical Networks Design And Installation

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8. CABLING
8.1 DC Cabling
In order to achieve the voltage needed for the connection to the inverter, 10 panels will be
connected in series, forming a string. 3 or 4 strings will be tied in parallel and connected to one
input of the string combiner box. For the connection of each string to the string combiner, a DC
cable, OLFLEX 1x4mm2 will be used. This is a flexible cable with insulation and mantle protection
of high durability elastic. The cables follow the standards HD 22.4 and are recommended for use
in moist or dry outdoors solutions. Different colors( red and black)will be used for signaling
depending on polarity.

Fig. 12 Olflex Solar Cable

At the cable edge there are cable terminals MC
MC-4
4 fit for P/V systems installations. The
solar cable will be fixed to the metallic bases with U/V resistant tire
tire-ups.
Cable specs:

Temperature operational spectrum -40C to 120C

Maximum allowed voltage 1.8KV DC
Expected life span > 25 years
UV protected
Can easily be installed outdoors, in pipes or channels
Insulation and shield from free halogens mix, extremely durable in high temperatures.
For installation
on special tools (crimping pliers) provided by the manufacturer are used.

Fig. 13 Cable terminals and crimping pliers

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Solar cables will be attached with UV-protected cable ties to the horizontal purlins of the
metallic structure. If the string combiner is not on the same table as the strings that connect to it,
then the solar cable will be buried at 0.6 m underground and protected with corrugated ducts.
For power transportation from the string combiner boxes to the input side of the inverters
we will use aluminum NAYY cable, 2x120 mm2. These cables will be buried at 0.80 m (under the
freezing temperature limit), between 2 layers of sand, in order to obtain cooler temperature,
better conductivity and protection from mechanical stress caused by heavy vehicles trespass or
others.

Fig. 14 NAYY cable

8.2 C Cabling
For the power transport from the inverters to the LV board of the substation, as well as
from the LV board to the transformer, the choice will be a 3-conductor per phase copper cable,
NYY, with a cross-section of 3x240 mm2. This cable will be installed to ensure minimum losses of
energy. Also, in order to ensure a minimum voltage drop, the inverters will be installed near the
substation.

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9. SECURITY SYSTEM
A security system in order to protect equipment from vandalism or theft and generally to secure
the unobstructed park operation will be installed according to the design of a specialized security
system provider.
The security system will typically consist of:

Alarm system
Cameras network
Light spots network system

9.1 Alarm system

Perimeter system of infrared beams installed 0.5 m inside perimeter fence.

Access system with pin code numerical pass, near the entrance.
Events registry system
GSM modem for data transfer to surveillance center.

In case of perimeter breaching of beam network, alarms and events are triggered to notify
security personnel.
9.2 Cameras network

Cameras network
Data recorders in the security station

The cameras have operational surveillance distance of 100m with zoom x10. Are installed in
such height, so can record malicious actions against equipment. The cameras network is
triggered by perimeter breaching. The recorder can store footage locally or can be sent via fast
network connection to a remote security center.
9.3 Lights
The purpose of the lights network is to provide luminosity enough, to allow sufficient cameras
recording and safe personnel trespassing that might visit the premises, during night time. It can
be activated manually from the light control board, or automatically by the perimeter breach.
The level of security measures can be tailored to the customer needs. The specs and prices are
indicative and apply to common cases. For the specific case, taking into account of the size of
the plant and the vandalisation history in the area, the security issue needs to be detailed in
depth with the beneficiary. Most probably permanent security personnel have to be allocated,
with a higher level security proposal.

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10. REMOTE MONITORING SYSTEM

The remote monitoring system proposed for the specific plant is from company Inaccess and
provides real-time supervision of the following data.
The system offers:
Turn- key solution for solar parks management and PR measurement.
Autonomous operation of the solar park.
Centralized management of the park.
Alarm detection and management.
Combination and correlation of alarms with all parameters and values received from the park
by intelligent software.
Immediate informing for any problem or failure so as to minimize the equipment downtime.
(Capability for SMS/email notification in case of critical alarms).
Periodical execution of equipment control and maintenance procedures according to the
specifications of the equipment manufacturers.
Measurement of the performance of the installed infrastructure and of the park as a whole.
Monitoring and recording of necessary data for the automatic creation of a variety of reports
concerning the supervised solar parks.
Secure and ciphered communication between the control center and the park for interception
avoidance.
Support of multiple and geographical distributed solar parks through a common control
center.

Fig. 15 Remote monitoring system

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11. MAINTENANCE AND WARRANTIES

11.1 Cleaning and Maintenance
Personnel will be assigned specific tasks for the scheduled park maintenance:

Visually inspection of the panels and act upon specific cases, but it is not recommended to
periodically clean or through water, besides the rain.
Keep vegetation low on height in order to keep ground in natural condition and seed low
plantation,in order to keep a level of natural moisture to keep ground layers and
underground cables, cool, therefore minimize losses.
Visually inspection structures, groundings, connections, fence, etc.
Adjust and keep calibrated security equipment, if needed.
Keep light network operational by changing lamps, etc.
Keep events book record registry.
Keep drainage system for pluvial water operational.

Regarding cleaning of the panels, it is recommended to follow the cleaning instructions provided
by the panel supplier. Most manufacturers recommends periodic cleaning of the PV modules to
ensure maximum power output. The glass surface of the PV modules should be cleaned with a
soft brush with the use of soft, clean water with recommended pressure less that 690kPA, typical
of the most municipal water systems. It is not recommended to use water with high mineral
content as it may leave deposits on the glass surface. Power or pressure washers and steam or
corrosive cleaning agents are not to be used for the cleaning of the modules.
In case of snow, the modules should be cleaned with a soft brush but in case of frozen snow or
ice it shouldnt be tried to taken out.
During maintenance visits, the following tasks will be checked:

Visually inspection of the panels and actions will occur upon specific cases.
Vegetation will be kept low on height in order to keep ground in natural condition. Low
seed plantation would be best to get planted, in order to keep vegetations height low and
also maintain a level of natural moisture to keep ground layers and underground cables,
cool, therefore minimize losses.
Visually inspection of structures, groundings, connections, fence condition, etc.
Adjust and keep calibrated security equipment, if needed.
Keep light network operational by changing lamps, etc.
Keep events book record registry.
Keep drainage system for pluvial water operational.

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11.2 Warranties
PANELS: This warranty is assigned by the manufacturer.
INVERTERS: This warranty is assigned by the manufacturer
SUBSTATIONS: 24 months.
BASES Alumil:
o
10 years anticorrosion warranty by the producer
o
25 years static sustainability
1 year warranty of good execution by the Contractor.
o
48 hours intervention for operations productive elements alarm.
o
5 days for other alarms not affecting production.

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