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The challenges of moving from 33 kV to 66 kV for offshore
wind farms

By Colin Pawsey

The development of large wind turbines, 5MW and upwards, installed further out to
sea requires the development of the entire wind farm infrastructure to support
them. Stepping up the inter-array voltage from 33 kV to 66 kV is increasingly being
considered as a crucial component of future wind farm design, and has the potential
to contribute significantly to cost reductions and higher yields. However, there are
several challenges for the industry to negotiate to implement this change, and the
effects on turbine structure, switchgear, transformers and cables must all be taken
into account.

Driving down costs

One of the key issues for the wind industry is the reduction of cost, both in terms of
wind farm construction and cost of energy. Back in 2008 the Caron Trust set up the
OWA (Offshore Wind Accelerator) R&D programme with the aim of reducing the cost
of offshore wind by 10% by 2015. The programme is a joint industry project which
involves nine offshore wind developers Dong Energy, E.ON, Mainstream
Renewable Power, RWE Innogy, Scottish Power Renewables, SSE Renewables,
Statkraft, Statoil, and Vattenfall who between them own 72% of the UKs licensed
capacity.

The OWA Research, Development and Demonstration Programme is focusing on five
key research areas to achieve cost reduction, and a move to 66 kV forms part of the
overall strategy. These five areas of development are:

Foundations developing new turbine foundation designs for 30-60m water
depths that are cheaper to fabricate and install.



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Access systems Developing improved access systems to transfer
technicians and equipment onto turbines for operations and maintenance in
heavier seas.

Wake effects improving the layout of large wind farms to reduce wake
effects and optimize yields.

Electrical systems Developing new electrical systems to reduce transmission
losses and increase reliability.

Cable installation improving cable installation methods.

The OWA estimates that a change to 66 kV for the inter-array voltage of wind farms
will result in a considerable cost saving, and is actively promoting the development
of the infrastructure required to support this change.


Source: The Carbon Trust

Advantages of moving to 66 kV

There are several advantages to using higher voltage arrays on offshore wind farms,
including the ability to use electrically larger substation transformers. These
substation transformers are significantly lighter than 33 kV transformers of the
same rating, and there is also the potential to reduce the number of substation


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transformers. Higher voltage will provide the opportunity to connect turbines in a
ring network to improve availability, while lower losses in array cables can also be
expected.

Analysis carried out by the Carbon Trust in 2012 into higher voltages included a
detailed comparison of 33 kV radial and ring array systems and 66 kV radial and
ring array systems. This included an analysis of all key technical components of the
system such as cables, switchgear, transformers and offshore substations, as well
as optimizing and comparing the inter-array designs. A detailed cost-benefit
analysis was carried out in order to compare the systems, which included CAPEX
(Capital Expenditure), operation and maintenance, cost of system losses, and cost
of losses due to cable failure for an assumed wind farm lifetime of 25 years.

The study concluded that higher voltage systems were found to exhibit NPV (Net
Present Value) improvements over the 33 kV systems, and that a key benefit of
moving to a higher voltage is the ability to implement ring array systems
economically and with viable electrical designs. In addition it was found that at 66
kV there is the possibility to remove a platform and connect all the turbines to a
single platform. This may prove to be an even greater advantage as wind farms
move further offshore and into deeper water and offshore platforms become more
expensive.

The report also concluded that housing equipment externally was found to have a
CAPEX impact that outweighed any operation and maintenance improvements, and
therefore recommended that equipment should be housed within the tower.
However, it was noted that there may be other advantages in housing equipment
externally, such as greater flexibility for wind farm developers to specify their own
electrical equipment.

The final recommendation of the analysis was that the offshore inter-array voltage
should move to 66 kV, and that the optimal solution is for wind turbine equipment
to be accommodated within the tower. In order to implement the 66 kV system, it
was recommended that a qualification test or tests should be encouraged for wet
type 66 kV designs, and that further engagement with wind turbine manufacturers
should be carried out to ensure that 66 kV wind turbines are developed.



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Challenges:

Turbine structures

The impact on turbine structures of the move to 66 kV is one factor that must be
considered. As larger turbines are developed for deep water, foundations and
turbine construction are developing to create new designs which are more cost-
effective to build, to install, and to maintain. As part of the Carbon Trusts analysis
work was also carried out to assess the increase in structural costs associated with
moving to a higher voltage inter-array system. Three options were considered:

1. All equipment placed inside the wind turbine tower.

2. Transformer outside and high and low voltage switchgear inside the tower.

3. Transformer and low voltage switchgear outside and high voltage switchgear
inside the tower.

It was assumed that any equipment outside the tower would need to be housed in
an external marine container, and although this gives the advantage of flexibility for
wind farm developers in equipment specification, the option to specify larger
equipment types, and improved access to HV equipment, it was found that the cost
of the container to house the equipment would be prohibitive. Despite concerns that
high voltage equipment may not fit inside the tower, components were identified
that could be incorporated into the tower, and as such any impact on structural
design would be minimal. However, the housing of equipment externally may still
become a viable economic option as the design of turbines and high voltage
equipment develops.

Switchgear and transformers

Although there is a slight cost penalty in terms of equipment, as transformers and
switchgear for 66 kV are more expensive, these costs should be outweighed by the
overall benefits. Hybrid GIS/AIS switchgear appears to be the best option for 66 kV
systems, and the Carbon Trusts cost analysis found that it would be considerably


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cheaper than full GIS equipment, which is specified on a project basis and can have
complex arrangements.

A slim type transformer was identified as the most promising transformer type, as
they are already in common use in 33 kV systems and fit within the wind turbine
tower. For 66 kV systems, a force-cooled transformer was identified and was found
to have reasonable costs when compared with 33 kV transformers.

Transformers and switchgear are commercially available for 66 kV, although there is
still potential for more efficient and cost effective components to be developed.
However, the lack of 66 kV cable is seen as the biggest barrier to moving to higher
voltage arrays.

Cables


Source: Narec



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Cable availability is the key issue the industry has to overcome to move to 66 kV
inter-array systems. Wet type cables without a lead sheath are currently used for
33 kV array systems, which are significantly cheaper than dry type cables which
incorporate a water-blocking lead sheath. The water blocking for wet type cables is
performed by XLPE or EPR insulation, and at present there are no commercially
available inter-array cables of this type that can operate at voltages higher than 36
kV.

The OWA estimates that over 6000km of cable will be required to build round 3 of
the UKs wind power development, but the industry faced a chicken and egg
situation in that cable manufacturers were reluctant to invest in the certification
process of a new 66 kV cable without guarantees of demand, while developers are
unable to specify a new array cable voltage when cables are not yet certified. To
resolve this issue and encourage development the Carbon Trust has awarded
funding of 400,000 between three cable manufacturers to qualify 3 different cost-
effective cable designs , as well as share the results from the qualification of a
fourth cable.

JDR will qualify a 3-core 630mm
2
, copper conductor, wet design, 66 kV cable.

Nexans will qualify a 3-core 630mm
2
, aluminium conductor, dry design, 66 kV
cable, and will share findings from their qualification of a 3-core 630mm
2
,
copper conductor, dry design, 66 kV cable.

Pyrsmian will qualify a 3-core 800mm
2
, aluminium conductor, 66 kV cable.

Test results from all four cables will be available in 2015, with extended test
programmes for some prototype cables expected to be complete by 2017. The OWA
estimates that although there will be a 12% increase in cable cost for 66 kV, there
will also be a 100% increase in transmittable power, so it is essential that cable is
developed to support 66 kV arrays.






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Testing and demonstration sites

For the move to 66 kV to become a reality there is also a need for testing and
demonstration of the system, and the National Renewable Energy Centre (Narec)
delivered a feasibility assessment, supported by ABB and the Crown Estate, to
identify potential UK sites to demonstrate 66 kV inter-array technologies.

Initial investigation assessed all planned UK offshore wind demonstration sites and
identified two potential candidates: Hunterston, North Ayrshire and Blyth,
Northumberland. Both were subsequently investigated for technical feasibility, cost
versus 33 kV implementation, and viability for LVRT (Low Voltage Ride Through).
Hunterston showed promise for demonstration purposes, but the existing
connection is 33 kV so the site would require a step up transformer resulting in
higher costs, and LVRT testing at 66 kV would not be practical. Blyth showed a
potential cost reduction for 66 kV (particularly for radial configurations) but at the
least cost parity, while LVRT testing would also be achievable.

Continuation in the development of a test site can be expected throughout
2014/2015, and demonstration will be crucial to the development of 66 kV systems.

Fukushima case study

Global demonstration and testing has already begun with the development of the
Fukushima floating offshore wind farm demonstration project. Funded by Japans
ministry of Economy, Trade and Industry, the project initially involved the
installation of one 2MW floating wind turbine, a 25MVA floating substation and a 66
kV underwater cable. The second phase planned for 2015 will include the
installation of two 7MW floating wind turbines. The project has been initiated to
assess economic feasibility and results will be made publicly available, providing
much needed information regarding 66 kV systems.

Summary

The move from 33 kV to 66 kV appears to be the natural one as turbines become
much larger and move further out to sea. However, there are many challenges for
the industry to consider, not least the design of certified cables for inter-array


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systems. Yet with cost reduction at the forefront of the wind industry in terms of
development and cost of energy, the move to 66 kV will be a vital component of
cost-effective wind energy in the future.



Colin Pawsey is a freelance technical journalist, focusing on new trends and
technologies in the renewable energy and automotive sectors. He is a regular
contributor and writing consultant to IQPC and Automotive IQ, and is also the
founder of copywriting agency Pure Copy.

Sources:
http://www.all-energy.co.uk/__novadocuments/30379?v=635060409652770000
http://proceedings.ewea.org/annual2012/allfiles2/1161_EWEA2012presentation.pdf
http://www.carbontrust.com/our-clients/o/offshore-wind-accelerator
http://www.carbontrust.com/media/508349/Carbon-Trust-OWA-All-Energy-2014-
Breanne-Gelattly.pdf
http://www.narec.co.uk/narec.co.uk/documents/presentations/7._narec_pmck_reta
_event_december_2013_final_-_paul_mckeever.pdf
http://www.abb.co.uk/cawp/seitp202/c3f68b2486248f5bc1257a520046d762.aspx
http://www.fukushima-forward.jp/pdf/pamphlet3.pdf