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The Update of IEC 61400-24 Lightning Protection of Wind Turbines
The Update of IEC 61400-24 Lightning Protection of Wind Turbines
The Update of IEC 61400-24 Lightning Protection of Wind Turbines
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Troels S. Sorensen
DONG Energy
troso@dongenergy.dk
DONG Energy, A.C. Meyersvaenge 9, DK-2450 Copenhagen SV, Denmark.
Abstract – The first edition of the IEC 61400 Wind Generator Systems – Part 24 Lightning Protection [1] was published as
a technical report (TR) in July 2002, and as such its scope was to present lightning and lightning protection to a relatively
young industry. It presented background statistical information on lightning damage to wind turbines and it gave guidance to
lightning protection best practices. Since then the wind power industry has developed rapidly towards even larger wind
turbines and into a booming and more mature industry in need of an industry standard for lightning protection. This is the
background for the update of the IEC 61400-24 under preparation, which transforms the TR into a full standard based on the
general lightning protection standards of the recent IEC 62305 series [2], on the general standards for EMC of the IEC 61000
series [3], the specific standards for electrical systems on machinery and the general standards for electrical systems, and with
regard to the blades, on both the latest research and on the air craft industry standards issued by SAE / EUROCAE [4-5].
1 INTRODUCTION
Wind turbines are the fastest growing source of electrical energy with annual growth rates of about 30 per cent in
recent years and totalling 94 GW generator capacity installed world-wide by the end of 2007. More than 20 GW of wind
power was installed in year 2007, which was also the year when the USA became the biggest market for wind power
with 5,2 GW of new wind power generation capacity (26% of the world market), followed by Spain 3,5 GW; China 3,4
GW; India and Germany both with 1,7 GW. Germany is still the world leading wind power nation with 22,2 GW of
installed wind power generation capacity [6].
In terms of lightning protection the numbers stated above would translate into tens of thousands of tall structures,
each of an average height of more than one hundred metres, placed at windy locations and therefore very exposed to
lightning; structures that also contain relatively complex electrical and control systems and that have rotating composite
blades up to 60 metres long. Given the frequency of lightning occurrences in the regions of the world where this new
expansion is taking place, all these new wind turbines will be hit several times by lightning during the 20 years in service
life. This makes lightning protection an important challenge, and it is obvious that given the numbers of wind turbines
now being installed it cannot be done on an individual wind turbine basis, but has to be met by the wind turbine industry
by implementing standardized lightning protection in their series-produced machines.
The IEC TC88 Project Team 24 preparing this new revision of the IEC 61400-24 has much stronger industry
participation compared with the working group who prepared the first edition. This is a clear indication of the
importance attributed to lightning protection by the wind turbine industry itself, which is also reflected by the fact that
today wind turbine manufactures employ their own lightning protection specialists, whereas previously lightning
protection of wind turbines was handled on behalf of the manufacturers by external consultants. One point to make is
that whilst the IEC 61400-24 is limited to horizontal axis wind turbines it is recommended that manufacturers of vertical
axis wind turbines to observe similar good practices as contained in the standard.
Fortunately, both research and experience accumulated over the last few decades have shown that wind turbines can
be effectively protected against lightning by applying the well-known and proven lightning protection techniques which
are described in the lightning protection standards and in the lightning protection literature. This is the case for the
electrical and control systems, and also for most of the wind turbine structure. The exceptions are the blades for which
new protection systems have had to be developed, and the large bearings of the mechanical drive train; these pose
special problems as they are in the direct down conduction path for the current when lightning attaches to the blades. As
indicated above , lightning protection of blades fabricated from composite materials represent a special challenge which
has been addressed in different ways by blade manufacturers, firstly on a trial and error basis, and over the last decade or
so using more dedicated research and development programs including field tests, laboratory tests and analytical work
[e.g. 7-9].
The update of the IEC 61400-24 focuses on how to apply existing standards for lightning protection, EMC, electrical
systems etc. to wind turbines in order to achieve effective lightning protection of electrical and control systems and the
general wind turbine structure. The update emphasizes testing as key to proving the validity of the lightning protection
system design. An effort has been made to describe a range of high voltage and high current tests for testing of blades,
originally developed and used successfully for qualification air craft structures [4], which have in recent years been
successfully adapted to testing of wind turbine blades and discrete components in the lightning down conduction system
of the wind turbine [e.g. 7-9].
In this paper the IEC TC88 project team 24 will take the reader on a brief tour of the new update of the IEC 61400-
24 while briefly familiarizing the reader with relevant background information. The reader should not use this as a
substitute for referring to the full standard when designing lightning protection for wind turbines.
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Fig. 1 - Three bladed horizontal axis wind turbine with tubular Fig. 2 - Generalised wind turbine nacelle design (Example of a
tower wind turbine with gear box)
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It is advisable always to obtain information about local lightning occurrence from authorities such as national
weather bureaus, and to consult other operators of wind turbines in the area or operators of other installations such as
local power companies to obtain information about local conditions, and if relevant particularly about occurrence of
upward lightning and winter lightning.
It is recommended that for calculation of collection area all wind turbines are modelled as tall masts with height
equal to the hub height plus one rotor radius. This applies to wind turbines with any types of blades including blades
made solely from non-conductive material such as glass fibre reinforced plastic (GFRP). It is recommended to include
local terrain variations to get an effective height for the wind turbine as illustrated in Fig. 3.
1:3
It is also recommended to consider the calculation of the collection areas of connected structures as illustrated in Fig.
4 for a wind turbine of height Ha and another structure of height Hb connected by underground cable of length Lc. (i.e.
according to IEC 62305-2 Annex A). Lightning flashes inside the narrow area AI along the cable route may penetrate to
and affect the cable directly, while lightning flashes inside the wider area Ai may induce transients and may cause pin-
hole punctures of the cable insulation. This approach can be extended to wind farms with many wind turbines, in which
case overlapping collection areas of neighbouring wind turbines should be divided between the wind turbines along the
line defined by the intersection of the 1:3 gradients.
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1:3 gradient
1:3 gradient
3 × Hb
3 × Ha Lc
Fig. 3 – Collections area of an installation with a wind turbine connected by a service line cable to another structure
(ρ is the resistivity of the soil).
C. Lightning protection of wind turbine sub components
The standard recommends application of the lightning protection procedures defined in IEC 62305 to wind turbines,
and recommends that all subcomponents should be protected according to LPL-I unless it is shown and demonstrated by
a risk analysis that a lower level is adequate.
Application of the rolling sphere method to a wind turbine is shown in Fig. 4 by which can be identified the parts of
the structure exposed to direct lightning flash attachment i.e. LPZ 0A according to the Lightning Protection Zoning
concept, as well as the areas protected by the structure itself LPZ 0B (e.g. the area on the ground close to the tower).
Furthermore in Fig. 5 is shown an example of application of the Lightning Protection Zoning Concept defining internal
LPZ 1 and LPZ 2 i.e. areas of the wind turbine with higher protection level and lower lightning parameter levels.
1
2
2
1
Fig. 4 –Application of rolling sphere to wind turbine Fig. 5 –Example of application of the Lightning Protection
Zoning concept to wind turbine
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C.1 Blades
The blades represent one of the two special lightning protection challenges unique to wind turbines. The blades are
complex in terms of their geometry and construction and up to more than 60 m long, made from fibre reinforced
composite materials, placed on up to more than 100 m high towers and rotating in a vertical plane (horizontal axis wind
turbines) – while exposed to direct lightning attachment. Wind turbine blades are the most exposed parts of the turbine,
as is clear when applying the rolling sphere method, which identifies most of the blade surfaces as Zone 0A (c.f. Fig. 4),
and experience the full electromagnetic and mechanical (pressure wave) impact and energy content from the lightning
current, the electric field and the magnetic field associated with lightning strikes. The blades therefore have to be
protected accordingly.
The criteria for adequacy of protection for blades are to show that the design and positioning of the lightning air
termination system on the blade ensure efficient lightning interception, and that the down conductor system can sustain
the effects of lightning current corresponding to the lightning protection level I (unless show by risk analysis that LPL-II
or LPL-III is sufficient as shown in table 2).
Protection Peak Current Specific Energy Average Rate of Current Rise Total Charge Transfer
Level [kA] Content [kA/µs] [C]
[kJ/Ohm]
I 200 10000 200 300
II 150 5600 150 225
III/IV 100 2500 100 150
Table 2 – Lightning Protection Levels
Although the rolling sphere method indicates that lightning may attach anywhere on most of the blade surfaces, it is
clear from field experience that the majority of lightning attachments are located at the blade tip, and that only a
minority attaches elsewhere on the blade. It is therefore concluded in the standard that the air termination system
positioning tools (rolling sphere, protective angle etc.) in IEC 62305-3 do not apply to wind turbine blades, and the
standard therefore requires that the ability of the air termination system and down conductor system to intercept
lightning strikes and conduct lightning currents must be verified by either of the following methods:
Furthermore, the standard describes known lightning protection methods for blades (e.g. the concepts shown in Fig.
6), how to consider the effects of electrically conducting components and parts, such as tip shafts, carbon fibre
composites and wiring for sensors in the blades in the lightning protection system design and how to conduct
appropriate testing to verify the design.
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A Receptor B C D
Down
conductor
Down
conductor
Metal mesh
Steel wire
IEC 1864/02
Fig. 6: Lightning protection concepts for large modern composite material wind turbine blades
C.3 Mechanical drive train and yaw system
The mechanical drive train represents the other significant lightning protection challenge that is unique to wind
turbines. This is because the mechanical drive train, with the large rotating bearings, shafts, gears and associated
hydraulic and electrical actuator systems, are in the direct path of the lightning current when lightning attaches to the
blades.
The standard recommends that all parts of the mechanical drive train that are subject to damage due to lightning
currents or lightning arcs between moving parts, for example bearings and actuators be protected by sliding contacts or
spark gaps. These components are designed to divert the lightning current away from the component to be protected or
reduce the lightning current flowing through the component to a level that the component can sustain and withstand. The
standard requires that the efficiency of such protection systems be validated by testing (see section H) and/or analysis,
and that the expected lifetime of wear parts such as sliding contacts and spark gaps shall be documented.
The standard requires that LEMP Protection Measures (LPMS) be provided to protect against damages and to avoid
failure of these systems. It is required that the protection is designed using the systematic approach of the Lightning
Protection Zones (LPZ c.f. Fig. 7) concept according to IEC 62305- 4 and using the appropriate methods including:
• Earthing
• Bonding
• Magnetic and electrical shielding and line routing (system installation)
• Coordinated SPD protection
• Ensuring adequate EMC immunity levels for systems and apparatus
• Isolation, circuit design, balanced circuits, series impedances, etc.
This systematic approach requires that the need for protection be determined for every circuit crossing a LPZ
boundary, and also be evaluated for long circuits within one zone (i.e. longer than 10 metres). The protection can be
achieved by using SPDs, by using shielded cables, by using shielding cable routes or combinations thereof – as indicated
in Fig. 7.
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In general, the standard refers to the relevant electrical standards for electrical low voltage systems and installations
incl. IEC 60204-1, IEC 60204-11 [10] concerning low and high voltage electrical systems for machinery respectively,
and IEC 60364 concerning electrical installations of buildings, and to IEC 61000-5-2 concerning (EMC) installation and
mitigation guidelines on earthing and cabling and of course to IEC 62305-4 Protection against lightning – Part 4:
Electrical and electronic systems within structures.
The standard requires that SPDs comply with IEC 61643-1 for low voltage power systems and with IEC 61643-21
for telecommunication and signalling systems, and that SPDs are selected and installed according to IEC 60364—4-44,
IEC 60364—5-53 and IEC 61643-12 for the protection of power systems, and IEC 61643-22 for the protection of the
control and communication systems [11-15]. Furthermore the standard describes the additional requirements for the
selection and installation of SPDs in wind turbine applications
The standard provides guidance on how to ensure coordination of SPDs, coordinate with withstand capabilities of
the components to be protected, and defines appropriate tests to verify the selection and design.
The standard recommends that metal oxide arresters without air gap according to IEC 60099-4 be used for protection
of high voltage power systems, and should be selected and applied in accordance with IEC 60099-5 [16-17], unless a
high voltage insulation coordination study is made to show that high voltage arresters are not needed.
LPZ 1
LPZ 2 Generator
High S S Shielded cable / S V
S Shielded cable / S G
P P P P P
voltage D D Shielding cable D D Shielding cable route D 3~
route
Fig. 7 – Example of LPMS division of electrical system into protection zones with indication of where circuits cross
LPZ boundaries and showing the long cables running between tower base and nacelle. Protection may be achieved by
using coordinated SPDs, by using shielded cables, by using shielding cable routes, or combinations thereof as needed.
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to achieve a low overall earthing resistance for the wind farm, to reduce potential differences between the different
structures of the farm, and to reduce the probability of direct lightning flashes to cable routes in the ground.
The standard discusses details of design of earthing systems for different types of wind turbine foundations, and
gives guidance on maintenance and inspection of earthing systems.
E. Personnel safety
Erection of large wind turbines on land takes several days when including the time it takes to assemble and
disassemble the very large cranes that are used. Offshore wind turbines on the other hand may be erected within less
than a day by the use of special vessels or jack ups. In addition, there is usually up to a few weeks of post erection
completion work before the wind turbine is commissioned. During this time many people are at work in, on and around
the wind turbine, and they are at considerable risk of being affected if lightning strikes the wind turbine.
Therefore the standard states that safety procedures with regards to lightning should be established, which should
include:
Different types of automatic warning systems are available for monitoring lightning activity in a warning area (WA)
around a construction site, which can be used to trigger an alarm when lightning activity is identified within the WA.
Such systems are typically based on detection of electrostatic fields from thunderclouds, detection of electromagnetic
impulses from lightning activity or combinations thereof. Lightning warning systems may not provide warning of all
lightning flashes, especially not of the first flash in a developing storm. Therefore it is essential that all personnel be
made aware of the signs of developing thunderstorms and the risk of lightning to their personal safety.
During construction work connections of cranes, generators etc. to the earthing system should be made as soon as
possible.
Platforms inside tubular towers are in general considered safe locations, as the tower is a near to perfect Faraday
cage. People in the wind turbine should be instructed to stop work and go to the closest platform inside the tower and
stay there until the thunderstorm has passed. Other safe places are inside metal roof vehicles, metal containers etc.
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Inspections should be made according to plans provided by the wind turbine manufacturer as part of his quality
assurance systems, and in the case of specific wind turbine projects provided by the wind turbine manufacturer in
cooperation with the owner/operator of the wind farm.
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• Location of possible leader attachment points and flashover or puncture paths on blades and other non conducting
structures,
• Optimization of the location of protection devices (air terminals, receptors),
• Flashover or puncture paths, along or through dielectric surfaces, and/or
• Performance of protection devices
There are three High Voltage Strike Attachment test arrangements, designated Test Setup A (Fig. 8 and Fig. 9), Test
Setup B (Fig. 10) and Test Setup C (Fig. 11). Test Setups A and B are most appropriate for tests of blade specimens
during design development and verification. Test Setup C is most appropriate for developmental tests to evaluate skin
panel construction and possible diverter strip configurations.
Each test arrangement is intended to result in initiation of electrical activity, such as corona, streamers and leaders, at
the test specimen (and not at the external electrode) as occurs at a wind turbine blade just before a lightning strike
attachment. Once ionization of the air at the test specimen is initiated, the streamer will progress toward the other
electrode, which has a large geometry and is intended to represent an electric field equipotential surface some distance
from a blade extremity. In this way the influence of the external test electrode on test results is minimized.
Overviews of the test arrangements showing the high voltage generator, test specimen, and external electrode in Test
Setups A, B and C are illustrated in Fig. 8, Fig. 9, Fig. 10 and Fig. 11.
The high voltage waveform used should be a double exponential switching type impulse voltage with rise times in
the order of 50-250µs and decay times in excess of 2000µs. This voltage waveform is selected since it is the most
representative of the electric field in the vicinity of a structure during an initial leader attachment.
Test Setup A is the most desirable arrangement, since it usually allows a larger dimension external electrode (i.e. a
conductive surface on the laboratory floor) and a more realistic electric field environment during the test around the
blade specimen to be provided.
HV generator
Voltage divider
e en
ad
Bl ecim
sp
Fig. 8 - Initial Leader Attachment Test Setup A (Specimen should be tested in several positions representing different
directions of the approaching leader)
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e en
ad
Bl ecim
sp
Test Setup B is intended to create a similar electric field arrangement about the test specimen as in Test Setup A
while allowing larger or heavier test specimens and support structures to be placed on the laboratory floor. In this
arrangement a large diameter electrode must be suspended above the test specimen. A large diameter is essential to
avoid non-realistic field intensifications due to the edges of the suspended electrode.
Test Setup C is most appropriate for developmental tests to evaluate or compare dielectric strengths of candidate
skin materials and/or local protection designs. However, tests of panels should not be employed for verification of
complete protection designs, since the panel specimens do not represent all significant features of the non-conducting
structures being verified.
Fig. 10 - Initial Leader Attachment Test Setup B (Specimen should be tested in several positions representing
different directions of the approaching leader)
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Electrode Electrode
d
Hardware Hardware
Mockup Mockup
D
Diverter a
Ground Wire
Dielectric
Panel
Fig. 11 - for Local Protection Device (e.g. diverter) Evaluations Test Setup C
A High Voltage Swept Channel test is defined which is be applicable to surfaces of a wind turbine blade that are
exposed to initial leader attachment when the blade is rotating, so that a leader may “sweep” along the surface a short
distance prior to first stroke arrival. The test, which is illustrated in Fig. 12 can be used to assess:
HV electrode
Blade motion
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Fig. 15 – Example circuit of a SPD discharge current test of a distribution board under service conditions.
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5 CONCLUSIONS
This paper has presented the update of the IEC 61400 Wind Turbine Generator Systems – Part 24: Lightning
Protection, which is currently being prepared by the IEC TC 88 Project Team 24. The update is a full standard based on
the general lightning protection standards of the recent IEC 62305 series, on the general standards for EMC of the IEC
61000 series, the specific standards for electrical systems on machinery and the general standards for electrical systems,
and with regards to the blades on the latest research and on the air craft industry standards issued by SAE / EUROCAE
6 REFERENCES
[1] IEC TR 61400-24, "Wind Turbine Generator Systems – Part 24: Lightning Protection", 2002, [Online]. Available: http://www.iec.ch
[2] IEC 62305, "Lightning Protection", 2006, [Online]. Available: http://www.iec.ch
[3] IEC 61000, “Electromagnetic compatibility (EMC)”, [Online]. Available: http://www.iec.ch
[4] SAE ARP 5412 / EUROCAE ED-84 “Aircraft Lightning Environment and Related Test Waveforms”, February 2005
[5] .SAE ARP 5416 / EUROCAE ED-105 “Aircraft Lightning Test Methods”, Section 5: Direct Effects Test Methods, 2005-3.
[6] Global Wind Energy Council, [Online]. Available: http://www.gwec.net.
[7] Larsen, F.M and Sorensen, T., “New lightning qualification test procedure for large wind turbine blades”. Proceedings of International
Conference on Lightning and Static Electricity, Blackpool, UK, 2003
[8] Madsen, S.F., “Interaction between electrical discharges and materials for wind turbine blades particularly related to lightning protection”.
Ørsted-DTU, The Technical University of Denmark, Ph.D. Thesis, March 2006
[9] Bertelsen, K., Erichsen, H.V., Madsen, S.F., ”New high current test principle for wind turbine blades simulating the life time impact from
lightning discharges”, Proceedings of International Conference on Lightning and Static Electricity, Paris, France, August 2007
[10] IEC 60204, “Safety of machinery, Electrical Equipment of machines”, [Online]. Available: http://www.iec.ch
[11] IEC 61643-1 “Surge protective devices connected to low-voltage power distribution systems – Part 1: Performance requirements and testing
methods”, [Online]. Available: http://www.iec.ch
[12] IEC 61643-12 “Surge protective devices connected to low-voltage power distribution systems – Part 12: Selection and application
principles”, [Online]. Available: http://www.iec.ch
[13] IEC 61643-21 “Low voltage surge protective devices - Part 21: Surge protective devices connected to telecommunications and signalling
networks - Performance requirements and testing methods”, [Online]. Available: http://www.iec.ch
[14] IEC 61643-22 “Low-voltage surge protective devices – Part 22: Surge protective devices connected to telecommunications and signalling
networks – Selection and application principles”, [Online]. Available: http://www.iec.ch
[15] IEC 60364 “Electrical installations of buildings”, [Online]. Available: http://www.iec.ch
[16] IEC 60099-4 “Surge arresters - Part 4: Metal-oxide surge arresters without gaps for a.c. systems”, [Online]. Available: http://www.iec.ch
[17] IEC 60099-5 “Surge arresters - Part 5: Selection and application recommendations”, [Online]. Available: http://www.iec.ch
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