115kV/ 34.

5kV Solar Power Plant

& Substation Design Project
DESIGN DOCUMENT

sdmay21-37
[email protected]
https://sdmay21-37.sd.ece.iastate.edu

Client: Black & Veatch

Advisor: Venkataramana Ajjarapu

Christof Barrier
Logan Hinkle
Keve Hughes
Brian Lemke
Cortland Polfliet
Nolan Rogers
Eric Schultz

Revised: October 25, 2020 / v2

 Executive Summary

Development Standards & Practices Used

This is primarily a design only project, so we will be adhering to IEEE standards
for reporting and documentation, as well as design layouts. We will also adhere to
standard practice when coding using AutoCAD or Revit. Additionally, we will
need to consider any limitations or requirements associated with construction in
specific states, specifically New Mexico.

Summary of Requirements
• Design 60 MW Solar Farm (Fall 2020)

o Select Panels
o Select Combiner Boxes
o Select Inverter Skids
o Select Location
o Design Layout of Farm

• Design Substation to handle Output from Solar Farm (Spring 2021)

Applicable Courses from Iowa State University Curriculum

• EE 201: Electric Circuits
• EE 230: Electronic Circuits and Systems
• EE 303: Energy Systems and Power Electronics
• EE 456: Power System Analysis I

New Skills/Knowledge acquired that was not taught in courses

• CAD/REVIT programming
• One-line diagrams
• Solar farm layout and distribution

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Table of Contents
1 Introduction 4
1.1 Acknowledgement 4
1.2 Problem and Project Statement 4
1.3 Operational Environment 5
1.4 Requirements 5
1.5 Intended Users and Uses 5
1.6 Assumptions and Limitations 5
1.7 Expected End Product and Deliverables 6
2 Project Plan 7
2.1 Task Decomposition 7
2.2 Risks And Risk Management/Mitigation 7
2.3 Project Proposed Milestones, Metrics, and Evaluation Criteria 7
2.4 Project Timeline/Schedule 8
2.5 Project Tracking Procedures 8
2.6 Personnel Effort Requirements 9
2.7 Other Resource Requirements 9
2.8 Financial Requirements 9
3 Design 10
3.1 Previous Work And Literature 10
3.2 Design Thinking 10
3.3 Proposed Design 11
3.4 Technology Considerations 13
3.5 Design Analysis 14
3.6 Development Process 14
3.7 Design Plan 14
4 Testing 15
4.1 Unit Testing 15
4.2 Interface Testing 15
4.3 Acceptance Testing 15
4.4 Results 15
5 Implementation 16

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6 Closing Material 16
6.1 Conclusion 16
6.2 References 16
6.3 Appendices 16

Figures
1. Project Schedule
2. Gantt Chart
3. Sample Solar Array Layout
4. Array Parameter Tool
5. Full Array and Half-Array Layouts
6. Multiple Array Layout
7. Plant Design Layout

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1 Introduction
1.1 ACKNOWLEDGEMENT
Black & Veatch will be guiding us as we work through this project.

1.2 PROBLEM AND PROJECT STATEMENT

This project sets out to develop a solar farm to increase the use of renewable energy at Black &
Veatch. Additionally, a power substation must be created which will allow for the harnessing and
distribution of the solar farm’s energy. This project is very important because regulations pushing
renewable energy on power companies are rapidly increasing and so Black & Veatch must begin to
take the necessary steps towards avoiding penalties from these regulations. On the other side of
this project, we can find importance through the students who are trying to learn about solar
energy and power distribution. Through this project, the team of students will be gaining real
world experience of what it would be like to work for a power company using calculations that are
produced from Black & Veatch’s internal documents.

The final goal of this project is to design a 60MW Solar Power Plant and 115kV / 34.5kV substation.
This project will be split up into two semesters with the first semester being the creation of the
solar plant design and the second semester being the creation of the substation design. In order to
accomplish this, the team of students must work together in unison with the mentors giving
deliverables that contain the following:

• Equipment sizing Calculations

• Solar layout drawings
• Solar panel string sizing design
• Electrical layout drawings (substation equipment)
• Grounding analysis and ground-grid developed with IEEE-80
• Bus calculations for substation
• Possibility of additional calculations (DC battery bank, Lightning protection, etc.)
• Creation of solar/substation design-optimizing tool
• Voltage drop calculations
• Trench fill
• Economic estimates

In order to stay on track with all of these deliverables, we will also be required to develop a detailed
engineer man-hour budget and schedule for this project; this will be a very nice way to plan the
overall project. Finally, the students will find a way to share their work with the Black & Veatch
engineers who will analyze the work we have done through the two semesters.

General Problem Statement

We, as a team, have been tasked with designing a 60 MW solar farm with accompanying substation
to add clean, renewable energy to the American energy grid. This project is a “from scratch” design,
and while we will be using resources provided to us, the overall design of the final project will be
our own creation.

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General Solution Approach

We will design a 60 MW solar farm and substation by selecting appropriate parts and land, and
then decide the most cost-effective way to combine and set up the farm. This consists of
appropriately sizing solar panels, combiner boxes, and inverters, as well as necessary parts for the
substation. We will accomplish this by using CAD or similar software to virtually build and assess
our designs to produce a more ideal final product.

1.3 OPERATIONAL ENVIRONMENT

This solar farm will operate outside in typically hot, sunny weather and also must be able to
withstand temperatures below freezing. It must also be resistant to common weather conditions of
the area, such as thunderstorms or snow.

1.4 REQUIREMENTS
Functional

• Must be able to operate in environmental conditions as described in section 1.3.

• Power rating at the solar farm of 60 MW
• Adhere to IEEE standards
• Maintain reliability throughout lifespan of project .

Environmental

• Parcel of land must be flat and continuous (i.e. no hills, creeks, ravines)
• High amount of average sunshine per year
• High irradiance on the land
• Must be near enough end users so energy produced is used.

Economic

• Plant must be able to produce enough kWh per year over the course of 10 years to recover
initial investment and operational costs.

1.5 INTENDED USERS AND USES

This solar farm will service the surrounding areas as a support to current infrastructure. This may
include spikes in commercial or residential power usage during the daytime.

1.6 ASSUMPTIONS AND LIMITATIONS

Assumptions

• Assumptions
• The sun will shine a consistent number of hours per year
• A consistent amount of energy will be generated and sold each year
• Power lost to inefficiencies in equipment/transmission will be constant

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Limitations

• The plant cannot operate at maximum power rating, as power is lost in wires, equipment,
and to indirect sunlight.
• The solar farm must be close to enough customers so that the power generated is used.
• Land must be flat and continuous (no creeks/ravines/steep hills).

1.7 EXPECTED END PRODUCT AND DELIVERABLES

There are deliverables for this project that will be required from both the mentors with Black &
Veatch alongside the mentors/professors from Iowa State. The deliverables that will be required for
our mentors from Iowa State include:

• Discussion posts covering various topics from the lectures.

• Bi-Weekly Project Reports
• Lighting Talks
• Overall Project Design Document

The weekly discussion posts will allow us to learn different processes that our mentors from Iowa
State think will help throughout the process of this project. The Bi-Weekly reports helps our own
group along with the mentors to keep track of where we are in the project. This involves us stating
current problems and solutions that we are dealing with and current parts of the project that we
are finishing and starting. The lightning talks are ways for us students to practice talking through
our project and giving verbal updates for our mentor’s kind of like how we would in the real world
to show our bosses our progress. This document is the last deliverable for our Iowa State mentors
which will serve as an all-in-one project description.

With the information given by Black & Veatch, we can expect to report the following deliverables:

• Equipment sizing calculations

• Solar layout drawings
• Solar panel string sizing design
• Electrical layout drawings (substation equipment)
• Grounding analysis and ground-grid developed with IEEE-80
• Bus calculations for substation
• Possibility of additional calculations (DC battery bank, Lightning protection, etc.)
• Creation of solar/substation design-optimizing tool

The equipment sizing calculations will be excel documents that Black & Veatch have outlined for
us to do. These outlines include built in formulas that will be completed throughout the semester
as our group puts everything together. The solar layout drawings are 2D models that will be created
in excel to give an easier-to-understand example of our project. The solar panel string sizing is a
part of the same equipment sizing calculation excel file as above and will help with knowing how to
finish the 2-D model. The rest of the calculations will be discussed in further length in the second
semester. The students have not been presented with how these calculations should be completed
yet.

All these deliverables will help us to maintain a steady workflow resulting in a well-documented
and complete project by the end of this course.

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At the end of the project, our client can expect to have a completed (2-D) virtual model of the solar
farm along with the power substation. This will include all the deliverables listed above along with
a presentation of the overall progress we made in this project. This presentation will include both a
meeting with all the students and mentors present in addition to this design document which lays
out the project as a whole.

2 Project Plan
2.1 TASK DECOMPOSITION
Parts Acquisition

• Select Solar Panels based on price, company, and power rating

• Select Combiner Boxes based on price, number of inputs, Amperage rating, and company
• Select Inverter skids based on capacity, inputs, cost, and company

Design

• Design high level model in order to better visualize final product

• Design farm layout within land requirements and accessibility
• Design component attachments based on part ratings and cost and power efficiency

2.2 RISKS AND RISK MANAGEMENT/MITIGATION

We will not be physically constructing a prototype for the 60MW solar plant, so the risks will relate
only to performance targets. We have assumed that the plot of land is perfectly flat, at the standard
elevation of New Mexico, and will have enough room for all components of the solar plant. One
possible risk is that the minimum temperature of the solar plant’s location will affect the solar
string voltage. To compensate for this, we set the minimum temperature to -40 degrees Celsius.
This ensures a risk factor of 0 because New Mexico simply does not get that cold at any point in the
year. We have designed the system so that the combiner boxes and inverters will all be of adequate
strength to handle all of their inputs, even with maximum solar output. The solar plant can also
store excess power to keep up production on days with less than optimal amounts of sunlight. This
means that projected solar output will not be a risk. The main risk is that we might not complete
our design in time. I would evaluate this risk at a probability of 0.25 because we are currently ahead
of schedule by at least 1 week. One way of making sure that this won’t happen is by asking our
mentors for help whenever we feel that we are falling behind. Our mentors have been great about
offering help when needed , and we are sure that they will try their best to answer any questions we
might have.

2.3 PROJECT PROPOSED MILESTONES, METRICS, AND EVALUATION CRITERIA

Key Milestones in our project are part selection, high level layout design, AutoCAD/Revit initial
Design, AutoCAD/Revit corrections, AutoCAD/Revit final draft. These milestones can be evaluated
by percentage complete, as well as projected efficiency for the AutoCAD/Revit designs.

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2.4 PROJECT TIMELINE/SCHEDULE

Figure 1 – Proposed Project Schedule

Figure 2 - Gantt Chart

2.5 PROJECT TRACKING PROCEDURES

Our group plans to use Microsoft Teams and Google Drive to communicate and collaborate on all
project materials. We will track progress by adhering to strict deadlines for the various tasks
necessary to complete the project, and holding team meetings once per week to discuss progress on
tasks and to determine if additional resources need to be reallocated to the completion of a specific
task.

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2.6 PERSONNEL EFFORT REQUIREMENTS
All tasks have been completed by dividing work amongst team members via our weekly group
meetings. The mentors have given the team tasks from the senior design schedule and they will
provide upcoming specific tasks outlined in the schedule in the coming weeks. These tasks will be
divided amongst the team members via the Gantt chart linked in section 2.4, and the person-hours
task table, an example is below.

2.7 OTHER RESOURCE REQUIREMENTS

We will require access to solar field modeling tools, such as the Array Design Parameter Tool we
used to model our initial solar field design. These will be provided by our mentors. We will also
need access to AutoCAD software for designing things later in the semester. We can get free access
as students so this will not pose a problem.

2.8 FINANCIAL REQUIREMENTS

Given that our project is simply designing the solar field, the only financial requirement is possible
future software costs. If our project was to completely build the solar plant, the cost would be
millions of dollars.

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3 Design
3.1 PREVIOUS WORK AND LITERATURE
The design of solar farms and substations has well established practices and methodologies to
maximize efficiency. Our mentors at Black & Veatch guided our design process to follow these
practices. The general layout of a solar array is strings of solar panels connected in parallel, forming
racks, which are then linked into combiner boxes. The combiner box outputs are then fed into
inverters, which connect to the transformer and into the power grid. Efficiency has been a constant
problem in solar power, as power is lost in equipment, transmission, and due to uncontrollable
variables, such as temperature. Some of the advantageous design choices involve strategic
placement of combiner boxes and skids to minimize the amount of cable used in the farm. The
graphic below shows a sample layout of a traditional solar array.

Figure 3 - Sample Solar Array Layout

3.2 DESIGN THINKING

Much of our design process has been driven by the guidance of our client, Black & Veatch. They
provided us with the specifications to meet in the array parameter tool, as well as with advice about
common design principles for solar farms. Some of the important decisions we made about the
design of our solar farm were the wattage of the solar panels, the location we would build the solar
farm, and the location of the inverters and skids with respect to the solar panels.

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3.3 PROPOSED DESIGN
So far, we have designated an initial layout of the panels, combiner boxes, and inverter skids. The
basic idea behind our thinking was to maximize our efficiency on wiring and solar power collection.
We made use of the array parameter tool with component choices to guide the layout we created.
Below we can see the parameters used in our array parameter tool:

Figure 4 - Array Parameter Tool

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Using this parameter tool, we determined that there would be 25 solar panels in each string,
resulting in 50 solar panels per rack. For the layout of the racks, we settled on 6 racks per row, with
34 rows per array. In each array, there will be 2 racks removed to provide space for the inverter
skid, and there will be a 35 ft wide access road running through the middle for maintenance. Based
on these calculations, each full array will produce 4.141 MW of power. Since our target power for
the entire solar field is 60 MW, we will need approximately 14 full arrays and 1 half-array. The
layout of a full array as well as the half-array is shown below.

Figure 5 - Full Array and Half-Array Layouts

Each blue/orange rectangle represents a single rack. The large box in the middle of the array
represents the inverter skid, while the smaller dark blue squares represents combiner boxes. Each
full array contains 10,100 solar panels, 17 combiner boxes, and one inverter skid.

The full combined layout of the ~14.5 arrays will have a total length of 2,684.59 ft and a total width
of 2,520 ft, resulting in a total area of 6,765,168.3 ft, approximately 155.3 acres. The proposed full-
sized layout is shown below.

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 Figure 6 - Multiple Array Layout

Having well-defined information on how to design a solar farm and substation has been very
helpful for us. It allows us to focus more on getting this piece of infrastructure built in a timely
manner - something important in a renewable energy industry that is continuously innovating and
creating more efficient products. However, one downside to having such rigid constraints is
removal of creativity in a way - we cannot go out and create something completely original the way
an artist might. Efficiency and conformity are rewarded in an industry like this; the most effective
plant designs are ones that amalgamate all the best parts of other plans.

When we get to the design aspect of the substation, there are even more rigid constraints and pre-
established norms to guide us in bus design configuration. It will be up to us to determine the
correct configuration for our needs when we reach that point.

3.4 TECHNOLOGY CONSIDERATIONS

Solar panel technology is evolving, and as a result, large amounts of equipment with vastly different
specifications is available. Higher wattage solar panels produce more energy in less space but are
more expensive and require equipment that can handle the larger load. Copper cables are more
efficient than aluminum cables, however they are significantly more expensive at the gauge

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required to transfer utility scale power. Sun tracking technology increases efficiency of the solar
panels and generates more power but involves more maintenance and higher installation costs. The
trade-off in equipment is usually power/efficiency for cost. Careful design is the only way to
minimize the impact of the tradeoffs.

3.5 DESIGN ANALYSIS

Our design from section 3.3 works well. It successfully meets all the requirements outlined for us by
Black & Veatch. The 410 W panels generate the 60 MW required using the least amount of space,
while not overloading the equipment and keeping the costs as low as we can. Our design iterations
have involved tweaking the number of panels in the arrays as well as trying out different types of
cable in our design.

3.6 DEVELOPMENT PROCESS

We have adopted a Waterfall development process for this project. This method makes sense for us
as our requirements have been laid out specifically for us by our clients and Black & Veatch, and
following with a high level design to detailed design is the most straightforward way to getting to a
final product.

3.7 DESIGN PLAN

Our design did not take into consideration intended users from section 1.5 because they do not
directly affect the parts of the design we have control over. Our intended users would affect factors
which were simply given to us like plant location and generating capacity. Factors we do have
control over (component choice, plant layout, and Revit model) do not change based on who the
intended users will be. Meeting our requirements is the central focus of our designs. The technical
nature of our project pushed us to design our solar plant layout to meet the constraints laid out by
Black & Veatch as closely as we could. This includes component selection (panels, inverters,
combiner boxes, and cables) as well as physical layout in the solar plant.
The figure below shows an abstract version of our design process which is centered around the
requirements we were given by our Black & Veatch mentors. The component choices module
includes the panels, inverters, combiner boxes, and cables for the solar plant. The physical layout
module encompasses string/rack sizes, array size and layout, panel tilt, and row spacing.

Figure 7 - Plant Design Flowchart

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4 Testing
Within our project, individual unit testing is not directly related to the desired outcome. The kind
of testing we will be doing is based more in iterative calculations that will meet predetermined
constraints such as in the array parameter tool and the upcoming voltage drop calculation and cost
analysis tools. Furthermore, because we are not actually physically building this project, no real
world tests need to be run, we will merely gain an understanding of what kind of challenges arise
when building and testing a utility scale solar farm in real life.

One of the challenges we encountered while testing within the array parameter tool was
misunderstanding of the terminology used because it is proprietary to the Black & Veatch. We were
able to clear this up by asking our peer mentors questions and researching other plant designs.

4.1 UNIT TESTING

Under the category of unit testing, we will be working with the solar farm and substation design as
sort of separate entities. Within the solar farm design, we have a few different parts that we will
spend multiple weeks on each (array parameter tool, voltage drop calculator, and trench fill tool).
For the purpose of our project these can be treated as individual units and will be continually
tested and improved as they are not physical but rather conceptual units.

4.2 INTERFACE TESTING

Interface testing has not been utilized, but as we transition into next semester it will be important
to synthesize our solar farm with the substation to ensure the designs work together to squeeze the
most efficiency possible out of the panels.

4.3 ACCEPTANCE TESTING

To show that we have met the design requirements, we will be presenting our findings, testing, and
designs with our peer mentors in our weekly meetings. There, we will receive feedback and
criticisms to ensure that we are moving forward in the right direction, implementing what is
wanted from them (the customer).

4.4 RESULTS
Thus far, we have completed our iterative testing of the array parameter tool which determines the
farm’s physical layout.
– Two main obstacles we had to overcome at first were getting familiar with all the
terminology and background information as well as getting an understanding of how the
array parameter tool works.
We have also completed the voltage drop calculations and cost analysis tool.
– Our cost analysis shows that we will lose money, but because of government subsidies and
bonuses for solar applications, our mentors say that everything will work out. The voltage-
drop calculations helped us determine how to efficiently wire our solar farm to minimize
losses.

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5 Implementation
We will not be directly involved with the implementation of this project. Our two semesters will be
two different design projects, and as such, we will not have time to see a fully built solar farm of our
design. Any implementation will be handled by Black & Veatch after Spring semester.

6 Closing Material
6.1 CONCLUSION
Summarize the work you have done so far. Briefly re-iterate your goals. Then, re-iterate the best
plan of action (or solution) to achieving your goals and indicate why this surpasses all other
possible solutions tested.

6.2 REFERENCES
List technical references and related work / market survey references. Do professional citation style
(ex. IEEE).

6.3 APPENDICES
Any additional information that would be helpful to the evaluation of your design document.
If you have any large graphs, tables, or similar data that does not directly pertain to the problem
but helps support it, include it here. This would also be a good area to include hardware/software
manuals used. May include CAD files, circuit schematics, layout etc,. PCB testing issues etc.,
Software bugs etc.

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