PV Installer Program-Participant Guide

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Introduction to Solar Energy

Solar Energy

An in-exhaustible source of Energy

which God has bestowed on us

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Solar Energy is a Electro Magnetic

Wave Radiation

• Radiation emanated from the sun at a temperature of 5000 o_K

• Magnetic Wave travels a distance of 1.5 * 10 8_km

• The Sun subtends and angle of 32’ with the earth

• Solar Constant i.e. Solar Radiation of 1395 W / m 2 _{in space}

Electro Magnetic Wave Radiation

• Gamma Rays 10

– 8

_{to 10}

– 4

_{µ m}

• X – rays 10

– 5

_{to 10}

– 2

_{µ m}

• Ultraviolet 10

– 2

_{to 1 µ m}

• Visible Spectrum 0.38 to 0.78 µ m

• Thermal Radiation – near infrared and far infrared 1 to 10

+ 3

_µ

m

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Azimuth angle of the sun:

Often def ined as the angle f rom due north in a clockwise direction. (sometimes f rom south)

Zenith angle of the sun:

Def ined as the angle measured f rom v ertical downward.

Position of the Sun

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 Declination = 23.45 * Sin (360*(284+n)/365)  Optimum Tilt angle = Latitude

for the ma ximum collection through out the year §Sea son Optimization tilt = (La titude - Declination)  Elevation and Azimuth

Cos θZ = Si n δ * Si n φ + Cos δ * Cos φ * Cos ω α = 90 - θZ

Solar Path Diagram

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Horizontal & Vertical Shadow

http://andrewmarsh.com/blog/2010/01/10/horizont al-and-vertical-shadow-angles 2/6/201 3 9 _{Corpora te Communication}

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Solar Radiation

Global

Direct

Diffused

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Photovoltaic

n-type se miconductor p-type se miconductor + + + + + + + + + + + + + + + - - - - - -

Physics of Photovoltaic Generation

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How PV Cell produce Electricity:

► When rays of sunlight hit the solar cell electrons are ejected from the atoms.

► Electrons are knocked loose from their atoms, which allow them to flow through the PN Junction to

produce electricity.

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2/6/201 3 31 _{Corpora te Communication}

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Solar PV Markets Capacity installed in 2011

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PV Module Production, Supply, and Demand

Metrics

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2/6/201 3 43 _{Corpora te Communication} 1,920.00 1,940.00 1,960.00 1,980.00 2,000.00 2,020.00 2,040.00 2,060.00

a-si Cd-Te CIS Mono-si Poly -si HIT 1,990.20 2,028.60 2050.7 2,053.10 2053.1 1966.4 El e ct ri ci ty E xp o rt e d t o T h e G ri d (M W h ) Fo r Fi xe d T ilt

Output vs Technology at Leh, Jammu & Kashmir State

1,600.0 1,650.0 1,700.0 1,750.0 1,800.0 1,850.0 1,900.0 1,950.0

a-si Cd-Te CIS Mono-si Poloy-si HIT 1,862.5 1,820.4 1,712.0 1,750.0 1,750.0 1,905.2 E le c tr ic it y E x p o rt e d t o T h e G ri d (M W h ) F o r F ix e d T il t

Output vs Technology at Bangalore, Karnataka State 1,600.0 1,650.0 1,700.0 1,750.0 1,800.0 1,850.0 1,900.0 1,950.0

a-si Cd-Te CIS Mono-si Poloy-si HIT 1,879.4 1,830.4 1,710.1 1,751.5 1,751.5 1,928.0 El e ct ri ci ty E xp o rt e d t o T h e G ri d (M W h ) Fo r Fi xe d T ilt

Output vs Technology at Bellary, Karnataka State

1,550.0 1,600.0 1,650.0 1,700.0 1,750.0 1,800.0 1,850.0 1,900.0 1,950.0

Output vs Technology at Charanka, Gujarat State

1,600.0 1,650.0 1,700.0 1,750.0 1,800.0 1,850.0 1,900.0 1,950.0

Output vs Technology at Jaisalmer, Rajasthan State

Bangalor e Charanka Leh 0.0 500.0 1,000.0 1,500.0 2,000.0 2,500.0 a-si Cd Te CIS Mo no-si Pol y- si HIT Bangalor e 1,8621,8201,7121,7501,7501,905 Br llar y 1,8791,8301,7101,7511,7511,928 Charanka 1,8661,8141,6901,7321,7321,917 Jaisalmer 1,8661,8141,6901,7321,7321,917 Leh 1,9902,02820512,0532053 1966 E le c tr ic it y E x p o rt e d t o t h e G rid (M W h )

Output vs Technology for Fixed Tilt

2/6/201 3 44 _{Corpora te Communication} 0.0 10.0 20.0 30.0 40.0

a-si CdTe CIS Mono-si Poly -si HIT 21.0 21.3 21.7 21.5 21.5 20.9 30.4 30.3 30.2 30.3 30.3 30.4 35.4 35.2 34.9 35.0 35.0 35.5 P e rc e n ta ge I n cr ea se in O ut p u t

Percentage Increase vs Technology at Leh, Jammu & Kashmir One-axis Polar Two-axis 0.0 5.0 10.0 15.0 20.0 25.0 30.0

Percentage Increase vs Technology at Bangalore, Karnataka One-axis Polar Two-axis 0.0 5.0 10.0 15.0 20.0 25.0 30.0

Percentage Increase vs Technology at Bellary, Karanataka One-axis Polar Two-axis 0.0 5.0 10.0 15.0 20.0 25.0 30.0

Percentage Increase vs Technology at Charanka, Gujarat One-axis

Polar Two-axis 0.0 10.0 20.0 30.0 40.0

Percentage Increase vs Technology at Leh, Jammu & Kashmir One-axis Polar Two-axis 0.0 5.0 10.0 15.0 20.0 25.0 30.0

Percentage Increase vs Technology at Bangalore, Karnataka One-axis Polar Two-axis 0.0 5.0 10.0 15.0 20.0 25.0 30.0

Percentage Increase vs Technology at Bellary, Karanataka One-axis Polar Two-axis 0.0 5.0 10.0 15.0 20.0 25.0 30.0

Percentage Increase vs Technology at Charanka, Gujarat One-axis

Polar Two-axis 0.0 10.0 20.0 30.0 40.0

Percentage Increase vs Technology at Leh, Jammu & Kashmir One-axis Polar Two-axis 0.0 10.0 20.0 30.0

Percentage Increase vs Technology at Bangalore, Karnataka One-axis Polar Two-axis 0.0 10.0 20.0 30.0

Percentage Increase vs Technology at Bellary, Karanataka One-axis Polar Two-axis 0.0 10.0 20.0 30.0

Percentage Increase vs Technology at Charanka, Gujarat One-axis_Polar

Two-axis 0.0 10.0 20.0 30.0 40.0

Percentage Increase vs Technology at Jaisalmer, Rajasthan

One-axis Polar Two-axis

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2/6/201 3 45 _{Corpora te Communication} 0.00 0.20 0.40 0.60 0.16 0.20 0.23 0.40 0.33 0.34 0.20 0.25 0.28 0.49 0.40 0.41 0.21 0.26 0.30 0.52 0.43 0.45 0.22 0.27 0.31 0.54 0.45 0.46 O u tp u t M W h /s q .m tr .

Output MWh/sq.mtr. vs Technology at Leh, Jammu & Kashmir Fixed One-axis Polar 0.0 0.2 0.4 0.6 0.2 0.2 0.2 0.3 0.3 0.3 0.2 0.2 0.2 0.4 0.3 0.4 0.2 0.2 0.2 0.4 0.4 0.4 0.2 0.2 0.2 0.4 0.4 0.4 O u tp u t M W h /s q .m tr .

Output MWh/sq.mtr. vs Technology at Bangalore, Karnataka Fixed One-axis Polar 0.00 0.20 0.40 0.60 0.15 0.18 0.19 0.34 0.28 0.34 0.19 0.22 0.24 0.42 0.35 0.41 0.19 0.23 0.24 0.43 0.35 0.42 0.20 0.23 0.25 0.44 0.36 0.43 O u tp u t M W h /s q .m tr .

Output MWh/sq.mtr. vs Technology at Bellary, Karnataka Fixed One-axis Polar 0.00 0.10 0.20 0.30 0.40 0.50 0.15 0.18 0.19 0.34 0.28 0.33 0.18 0.22 0.23 0.41 0.34 0.40 0.19 0.23 0.24 0.43 0.35 0.42 0.20 0.23 0.25 0.44 0.36 0.43 O u tp u t M W h /s q .m tr .

Output MWh/sq.mtr. vs Technology at Charanka, Gujarat Fixed_One-axis

Polar Two-axis 0.00 0.20 0.40 0.60 0.15 0.18 0.20 0.35 0.29 0.34 0.19 0.22 0.24 0.42 0.35 0.41 0.20 0.23 0.25 0.44 0.44 0.43 0.20 0.24 0.26 0.45 0.45 0.44 O u tp u t M W h /s q .m tr .

Output MWh/sq.mtr. vs Technology at Jaisalmer, Rajasthan Fixed One-axis Polar

Performance rating

Technical Commercial 5.00 7.00 9.00 11.00 13.00 15.00 17.00 19.00

a-Si CdTe CIS mono-Si Poly-Si HIT

Performance rating for fixed tilt at different places

Bellary Bijapur Charanka Jaisalmer Leh 5.00 7.00 9.00 11.00 13.00 15.00 17.00 19.00

a-Si CdTe CIS mono-Si Poly-Si HIT

Cost Driven rating for fixed tilt at different places

Bellary Bijapur Charanka Jaisalmer Leh

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Inspection

Plan of

Civil Foundations

for Solar Power Plants

 IS 1498:1970 – Classification & identification of soils for Engineering purposes  IS: 1199 – 1959 – Tests on fresh concrete

 IS: 13311 (Part 1,2) – 1992 – Tests on hardened concrete  IS 516:1959 – Methods of tests for strength of concrete

 IS: 2720 (Part II) – 1973 – Tests on soil – To determine w ater content in soil  IS: 2720 (Part 4) – 1985 - To determine the particle size distribution of soil  IS: 2720 (Part 5)–1985-To determine the liquid limit and plastic limit of soil  IS: 2720 (Part 8) – 1983 - To determine the maximum dry density and the

optim um m oisture content of soil

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Introduction to Soil

types for Foundations

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5 5

Soil Map of INDIA:

What is Soil?

Mineral

45%

Air

25%

Water

25%

Organics

5%

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7

GRAVEL

SAND

Clay

_Silt

Minerals

Soil Groups

Soil Type Gradation Plasticity Gravel – G Sand – S Silt – M Clay – C Organic – O Well Graded – W Poorly Graded – P High Plasticity – H Low Plasticity – L

Soil type & particle size distribution as follows:

• Gravel : 80 – 4.75 mm

• Sand : 4.75mm – 0.075mm (75 micron) • Silt : 75 – 2 micron

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9 9

Soil Type Allowable Bearing (lb/ft2 - Pound per square foot )

Drainage BEDROCK 4,000 to 12,000 Poor GRAVELS _3,000 _Good SAND 2,000 Good SILT _1,500 _Medium CLAY 1,500 Medium ORGANICS _{0 to 400} _Poor

Estimated Soil Load Bearing Capacities

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Sand and gravel –

Best

Medium to hard clays –

Good

Soft clay and silt –

Poor

Organic silts and clays –

Undesirable

Peat –

No Good / Avoid

Peat is an accumulation of partially decayed vegetation matter or organic matter.

Soil Strength Classification for Foundations

Laboratory tests for Soil

Follow ing laboratory tests are to be carried out to determine the physical and engineering properties of soil samples:

1. Dry density and moisture content - (IS 2720 part – 2 & 29) 2. Particle size analysis - (IS 2720 part – 4:1985) 3. Specific gravity - (IS 2720 part– 3/sec2:1980) 4. Shear test - (IS 2720 part – 11:1986) 5. Consolidation test - (IS 2720 part – 15:1986)

6. Free swell test - (IS 2720 part – 40:1977 & 41:1977) 7. Consistency Limits

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Soil Samples

Disturbed samples: which do not represent exactly how the soil was in its natural state before sampling.

► Disturbed samples are used for the more simple tests that will be

performed and particularly for those tests which can be performed by self in the field.

Undisturbed samples: which represent exactly how the soil was in its natural state before sampling.

► Undisturbed samples are necessary for the more sophisticated tests

which must be performed in the laboratory for more detailed physical and chemical

analyses. Undisturbed samples must be collected with greater care for they should represent exactly the nature of the soil.

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Introduction to Foundations

The soil beneath the structures responsible for carrying the loads is called FOUNDATION.

The general misconception is that the structural element which transmits the load to the soil(such as a footing) is the foundation. The figure below clarifies this point.

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Forces acting onto Foundation

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Classification of Foundations

► Shallow foundations are placed at a shallow depth beneath the soil

surface. They include footings and soil retaining structures. The depth is generally less than the width of the footing and less than 3m.



Shallow Foundations



Deep Foundations

► Deep foundations are commonly using piles. They are embedded very

deep into the soil. They are usually used when the top soil layer have low bearing capacity. Deep foundations are usually at depths deeper than 3m.

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19 Footing Footing

D

f

B

Footing

Ground Surface C o lu m n

P

For Shallow Foundation = Df < 4B

Shallow Foundation

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Pile

Hammer

Shaft

Pre bored hole Poured in place fill

Deep Foundations

Ground Surface

Df

B

For Deep Foundation = Df > 4B

Laboratory tests for Concrete foundations

► Tests on Fresh Concrete

1. Slump test: To determine the strength of fresh concrete by slump test as per IS: 1199 - 1959.

2. Compacting factor test: To determine the strength of fresh concrete by compacting factor test as per IS: 1199 - 1959.

3. Vee-Bee test: To determine the strength of fresh concrete by using a Vee-Bee consistometer as per IS: 1199 - 1959.

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Laboratory tests for Concrete foundations

► Tests on Hardened Concrete:

1. Non-destructive tests

a. Rebound hammer test: To assess the likely compressive strength of concrete by using rebound hammer as per IS: 13311 (Part 2) - 1992. b. Ultrasonic pulse velocity test: To assess the quality of concrete

by ultrasonic pulse velocity method as per IS: 13311 (Part 1) - 1992. 2. Compression test(Destructive): To determine the compressive

strength of concrete specimens as per IS: 516 – 1959.

Clear horizontal distance between reaction supports

and test foundation

a) For pad and chimney, grillages, concrete block foundations or buried anchors:

L = e + 0,7 x a (m)

Where,

e is the width of foundation in metres; a is the depth of foundation in metres;

L is the distance between nearest points of reaction supports.

b) For concrete piers, driven piles, drilled and grouted piles, or helix anchors:

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Figures:

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Types of PV Foundation used for Solar Power Plants:

This includes any of the following foundations:

 Concrete pier  Driven post  Screw piles

 Precast or cast-in-place concrete ballast

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Concrete pier

o Make sure the bottom of the footing rests on undisturbed soil

free of organic material.

o Uses reinforcing bar to firmly

connect the footing at the base to the concrete pier.

o At the top, a metal post base

connects the concrete pier to the mounting structure.

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Driven pile systems

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Driven pile systems are often found to be the more favorable choice based on cost, installation time, materials, and environmental impact.

Screw piles

• Screw piles are a steel

screw-in piling and ground anchoring system used for structure foundations.

• The pile shaft transfers a

structure's load into the pile.

• Screw piles are also

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Screw piles or Ground screws

Helical steel plates are welded to the pile shaft in accordance with the intended ground conditions.

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Precast or cast-in-place concrete ballast

 Ballasted footings are designed for mounting photovoltaic

solar panels quickly.

 Capable of relocation and reuse, the footings are intended for

use in demanding applications, where panels need to be

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Pile Foundation for Solar PV - Video

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Solar Photovoltaic (PV)

System and Safety Measures

1

Key Elements of a PV System

load Energy source power conditioning Energy conversion Inverter Charge Controller PV Array Energy distribution load center Battery Energy storage Electric utility network

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3

Solar PV Safety involves

1. Working safely with photovoltaic systems 2. Conducting a site assessment

3. Selecting a system design

4. Adapting the mechanical design to the site 5. Adapting the electrical design to the site 6. Installing subsystem & components at site 7. Performing a system checkout and inspection 8. Maintaining and troubleshooting the system

**OSHA* Safety Categories**

> Personal Protection Equipment (PPE) > Electrical

> Falls

> Stairways and Ladders > Scaffolding

> Power Tools > Materials Handling > Excavation

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5

Personal Protection Equipment (PPE)

Personal Protection Equipment

Responsibilities

Employer

Assess workplace for hazards.

Provide personal protective equipment (PPE). Determine when to use.

Provide PPE training for employees and instruction in proper use.

Employee

Use PPE in accordance with training received and other instructions.

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7

Examples of PPE

Eye

Safety Glasses, Goggles

Face

Face Shields

Head

Hard Hats

Feet

Safety Shoes

Hands and arms

Gloves

Bodies

Vests

Hearing

Earplugs, Earmuffs

Body Part Protection

Equipment

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9

Preventing Electrical Hazards:

PPE

 Proper foot protection (not tennis shoes)

 Hard hat(insulated - nonconductive)

 Rubber insulating gloves, hoods, sleeves, matting, and blankets

Selecting the Right Hard Hat

Class A

>General service (building construction, ship building, lumbering)

> Good impact protection but limited voltage protection

Class B

> Electrical/utility work

> Protects against falling objects and high-voltage shock and burns

Class C

> Designed for comfort, offers limited protection

> Protects against bumps from fixed objects, but does not protect against falling objects or electrical shock

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11

Hand Protection

Electrical Injuries

There are three main types of

electrical injuries:

> Electrocution or death due to

electrical shock

> Severe burns

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13

Dangers of Electrical Shock

> Currents above 10 mA* can paralyze or “freeze” muscles.

> Currents more than 75 mA can cause a rapid, ineffective heartbeat & death will occur in few minutes unless a

defibrillator is used.

> 75 mA is not much current – a small power drill uses 30 times as much.

* mA = milliampere = 1/1000 of an ampere

Personal Fall Arrest System

(PFAS)

Guardrails Safety Net

Fall Protection Options

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Must be independent of

any platform anchorage

and capable of

supporting at least 5,000

pounds (2268 kg)

Safety Line Anchorages

Ladder Angle

Non-self-supporting ladders

(that lean against a wall or

other support):

Position at an angle where

the horizontal distance from

the top support to the foot of

the ladder is 1/4 the working

length of the ladder.

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Grounding

> Grounding creates a low -resistance path from a tool to the earth to disperse unwanted current.

> When a short or lightning occurs, energy flows to the ground, protecting you from electrical shock, injury and death.

Improper Grounding

>Tools plugged into improperly grounded circuits may become energized.

>Broken wire or plug on extension cord

*Some of the most frequently violated OSHA standards

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Unsafe Installation Practices - Photos

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Site Selection, Resource Assessment

&

Energy Yield Estimation

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Site Selection

3 Good Layout

Good Layouts Hapezoidal Layouts

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Improper Site Selection

Plan for Rock Blasting

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Compromising With Placing Modules

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Good Topography

Site Survey & Investigation

Some of the other major factors that are to be considered

are

• Atmospheric effect on Solar Radiation

• Daily and Seasonal Temperature Variations

• Site proximity to natural disaster prone areas

• Site climatic conditions with regards to wind speeds,

saline atmosphere conditions etc.

• Site land topography. This will impact on the civil

foundation requirements

• Proximity for power evacuation

• Proximity to polluting industries

• Easy site access

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Cognizance for site selection

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Solar Resource Assessment

Step 1

Type the following link in the web browser

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Solar Resource Assessment

Step 2

Click on Meteorology and Solar Energy section. The page as detailed below will be displayed

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Solar Resource Assessment

Step 3

• Click on Enter Latitude and

Longitude part of Data tables for

a particular location. The following page will be displayed • This is known as Login screen. User has to enter

– E-Mail ID

– Password of his choice – Re enter the same password in third field

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Solar Resource Assessment

Step 4

After entering all the details, by clicking on Submit button, the following screen will appear

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Solar Resource Assessment

Step 5

• If the user is interested in solar radiation assessment in Delhi, one has to enter the following values in the latitude and longitude field of the screen.

Latitude : 28.38 N Longitude : 77.12 E

After entering the values, the screen will be as shown. Then, Click on Submit

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Solar Resource Assessment

Step 6

Choose parameters as per your requirement

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Solar Resource Assessment

Step 7

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Energy Yield Estimation

The following stage of evaluation is to carried out while designing / verifying

• Weather data NASA / METEORNOM • Simulation programme

• Choice of system components (Max. efficiency components) • Software to be used

- PVsyst - RETScreen

- System Advisory Model - TRANSYS

- PYSOL • Simulation • Analysis of yield

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Energy Yield Estimation

Case Study

To design a 5MWp solar PV grid-connected power plant at a designated location in Bangalore

Design Inputs • Site Details

– Bangalore , Latitude-13 0_{Longitude- 77}0

• DC Plate Rating – 5 MWp

• Technology

– Thin Film Technology • Inverter

– Central Inverter

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Energy Yield Estimation

Option : Project design, System : Grid-Connected

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Energy Yield Estimation

Click on Project

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Energy Yield Estimation

Select ‘New Project’ enter the relevant data and then click ‘Site and Meteo’

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Energy Yield Estimation

Enter relevant data

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Energy Yield Estimation

Click ‘Open’ to enter the Location parameters of the site

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Energy Yield Estimation

Geographical Parameters

Enter Latitude, Longitude, Altitude etc. and go to ‘Monthly meteo’ tab to see the irradiation data

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Energy Yield Estimation

Irradiation Data

Irradiation unit can be chosen as required and click ‘OK’.

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Energy Yield Estimation

Situation & Meteo

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Energy Yield Estimation

Operating temperature

Depending on site choose summer operating temperature for Vmpp Min design (the default is 60⁰ C) and click ‘OK’

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Energy Yield Estimation

Orientation

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Energy Yield Estimation

Tilt

• Click ‘Unlimited Sheds’ enter the ‘Plane Tilt’, ‘Pitch’, ‘Coll. band width’ and select the ‘Electrical Effect’ and click ‘Show Optimisation’

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Energy Yield Estimation

Shading loss

Shading Loss is displayed in this window. Close this window and ‘OK’

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Energy Yield Estimation

System

Click ‘System’

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Energy Yield Estimation

Module and Inverter selection

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Energy Yield Estimation

String definition

Select ‘Mod. In series’, enter ‘No. strings’ and click ‘Detailed Losses’

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Energy Yield Estimation

PV Filed losses (Thermal)

Enter ‘NOCT coefficient’ as given in Module datasheet and go to ‘Ohmic Losses’ tab

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Energy Yield Estimation

PV Field - losses (Ohmic)

Enter ‘DC circuit loss fraction at STC’, choose ‘Significant length’ and enter ‘Loss fraction’, ‘External transformer’ and enter the ‘Iron loss’ & Inductive loss’ also enter the Vac and go to ‘Module Quality -

Mismatch’ tab.

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Energy Yield Estimation

PV Field – losses (Module Mismatch)

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Energy Yield Estimation

PV Field - Losses (Soiling)

Select the ‘Soiling Loss’ of 3% and go to ‘IAM Losses’ tab

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Energy Yield Estimation

IAM Losses

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Energy Yield Estimation

Click OK

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Energy Yield Estimation

Simulation

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Energy Yield Estimation

Simulation Parameters

Click ‘Simulation’

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Energy Yield Estimation

Simulation Progress

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Energy Yield Estimation

Simulation Results

Click ‘Report’

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Energy Yield Estimation

PVSYST Design Report

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Energy Yield Estimation

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Energy Yield Estimation

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PHOTOVOLTAIC (PV)

– INSTALLER

GUIDE

Objective

• Verify System Design

• Managing the project

• Installing electrical components

• Installing Mechanical components

• Completing system Installations

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Introduction

Balance of system (BOS) component include all mechanical of electrical equipment and hardware used to assemble and integrate the major components in a PV system

Example of BOS components include:

3

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Verify system Design

• Determine Clients Need

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Review Site Survey

• Obtaining the necessary information during a site survey helps plan and

execute PV installations in a timely and cost effective manner.

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Array Location

9 1. Enough Area to get maximized energy 2. Is it shaded?

3.Is the structure strong enough?

5. How far the array will be mounted from other equipments? 4. How will the array be mounted?

Array Location

How will the array be installed & maintained? Will the array be subjected

to damage or accessible to unqualified person?

Are there any local codes or wind load concerns for areas of PV installation?

Are there additional safety, installation or maintenance concern?

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Array Area

 For multiple rows of tilted racks or for tracker installation additional

spacing is required between each array mounting structure to prevent the row to row shading.

 Additional area is required for installation of other equipments. Usually

for 1 KW dc crystalline power plant we need approximately 80 to 100 sf of surface area.

 As a thumb rule we can say that for 1 KW power plant approximately 16

square meter area is required.

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Perform a shading analysis

• PV array should be unshaded at least 6 hours during the middle of the day to produce the maximum energy possible.

• Ideally there should be no shadow between 9 a.m. and 3 p.m. solar time over the year, since the majority of solar radiation and peak system output occur during this period.

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Sun Path finder

13

Array mounting method.

• PV array can be mounted on the ground, rooftops and other structures that

provide adequate protection, support and solar access. The site conditions and Results of the site survey usually distance the best mounting system location and approach to use.

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Array mounting systems

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Building integrated

Mounting System

Roof Structure and conditions

Key points:

1. Check out the roof’s load bearing capacity and its underlying structures so that it can bear the additional load.

2. A civil engineer need to calculate the load with respect to local code compliance. We can also refer to standard ASCE 7 – minimum loads for buildings and other structures.

3. A standard roof mounting structure weighs between 3 and 5 pounds per square feet which is fine for most roofs designed to recent standards.

4. A span table can help to quantify the load bearing capabilities of roof trusses or beams. The website for this is www.solarabcs.org.

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Roof Structure and conditions

1. Wind loads are the primary concern for roof top m ounting systems. For hurricane prone regions the design wind load can be as high as 150 m ph w hich can exceed the actual wind load of 50 PSF and m ore in some corners of roof or structure. A structure engineer is required for the approval of the structures w ith respect to the wind load design of the array.

2. Before deciding the PV array mounting system verify with the m ounting system supplier that the hardware is appropriate for the given application.

3. For com m ercial roof m ounting system we can use the ballasted mounting system. This is significantly heavier than mounting system designed for direct structural attachments. But this system needs special load calculation. The m ain advantage is the possibility of roof leaks is greatly diminished.

17

BOS Location

1. Selection of appropriate location for all the BOS.

2. The BOS have to e w eather resistant. They may need to be installed in the w eather resistant enclosures. For this w e can refer to article 110 from NEC. 3. Avoid installing electrical equipments in locations exposed to high

tem perature and direct sunlight and provide adequate ventilation and cooling for heat generating equipments like inverters, generators, charge controllers etc. It is always better to have proper IP rating for these equipments to avoid damage from rain, dust, chemical and other environmental factors.

4. Battery location should be protected from extreme cold area because this will reduce the available capacity. They should be installed as per NEC 480. 5. Protection should be taken to prevent the attack from insects, rodents and

(90)

Confirm System Sizing : Size module mounting Area

• If site is selected for array location, it is necessary to determine whether the place is enough for the proposed number of PV modules.

• For Areas with NON-rectangular shapes, determine the amount of usable area can be challenged.

• Access to the modules must be provided in case system maintenance is needed.

• Smaller array surface area are required to generate the same amount of power with higher efficiency modules.

19

Confirm System Sizing : Arrange Modules in mounting area

• S itting the PV array in the available Mounting area can have a large impact on the performance of a PV array.

• Each set of modules in a series string must be oriented in the same direction if the string is to produce its full output potential.

• Is it possible to split a string between two roof faces, provided the modules keep the exact same orientation

(91)

21

Confirm System Sizing :Review Energy Storage Systems

• Capacity is a measure of battery energy storage, commonly rated in Ampere-hour

• Rate of charge or discharge is expressed as a ratio of the nominal battery capacity to the charge of discharge time period in hours.

• Usable capacity is always less than the rated battery capacity. Operational factors that effect available battery capacity include discharge rate, cut-off voltage, temperature and Age of battery

• A nominal 100 Ah battery discharged at 5 amps for 20 hours is considered a C/20, or 20 hour discharge rate

(92)

Confirm System Sizing :Review Energy Storage Systems

23

• The battery state of charge is related to the concentration of sulfuric acid

concentration. This is measured by specific gravity.

• Specific gravity is the ratio of the density of a solution to the density of

water.

• A fully charged lead acid cell has a typical specific gravity between 1.26

and 1.28 at room temperature.

• The specific gravity may be increased for lead-acid battery used in cold

weather applications. Conversely, the specific gravity can be decreased for application in warm climate.

• In very cold climate the battery should be protected from freezing by

limiting minimum temperature in a suitable enclosure or by limiting the Depth of Discharge.

Confirm System Sizing :Review Energy Storage Systems

Depending on the application or site requirement many factors are considered to select the battery and for system design as follows:

• Electrical properties: voltage, capacity, charge/discharge rates • Performance: cycle life vs. DOD, system autonomy

• Physical properties: size and weight • Maintenance requirements: flooded or VRLA

• Installation: Location, structural requirements, environmental conditions • Safety and auxiliary systems: racks, trays, fire protection, electrical BOS • Costs, warranty and availability.

(93)

Confirm System Sizing: Review Energy Storage System

25 Electrical Properties: voltage, capacity, charge/discharge rates Performance: cycle life Vs. DOD, system autonomy

Physical properties: Size and weight

Maintenance requirements: Flooded or VRLA

Installation: location, structural requirements, environmental conditions

Safety and auxiliary systems: racks, trays, fire protection, electrical BOS

Costs, w arranty

and availability

Confirm System Sizing :Review Energy Storage Systems

• Racks and trays are used to support battery systems and provide electrolyte containment

• Racks can be made from metal, Fiberglass or other structural non conductive material.

• Metal racks must be painted.

• Due to potential for ground faults, metals or other conductive battery tracks are not allow ed for open Vent flooded lead acid batteries more than 48 Volts nominal.

• If batteries are connected in series to produce more than 48 V, then the batteries must be connected in a manner that allow s the series strings of batteries to be separated into strings of 48 V or less for maintenance. • Overcurrent protection device or other such protective equipment's should be

(94)

Charge controller operations

• A battery charge controller limits the Voltage and current delivered to battery

from a charging source to regulate state-of-charge.

• A CC is required in most PV systems that use battery storage.

• PV array must not be capable of generating voltage or current that will

exceed the CC input voltage & current

• The CC rated continuous current must be 125% of the PV array Shot circuit

O/p current.

• The CC maximum i/p voltage should be greater than the maximum system

voltage

27

Charge controller operations : Set points

Set Point:

Set points are the battery voltage levels at w hich a charge controller performs regulation or control functions. The [proper regulation set points are critical for optim al battery charging.

1. Regulation Voltage (VR) is the maximum v oltage set point the controller allows the battery to reach bef ore the array current is disconnected or limited. 2. The array Reconnect Voltage (ARV) – f or interrupting ty pe controllers, is the v oltage set point at which the array is reconnected to charge the battery

3. Low Voltage Disconnect (LVD)

– def ines the maximum battery depth of

discharge at the giv en discharge rate. 4. Load Reconnect Voltage (LRV)- the set point where load are For a ty pical lead acid cell a LVD set point of 1.85

VPC to 1.91 VPC corresponds to a DOD of 70 to 80% at C/20 discharge rates or lower.

Load

Battery Bank

(95)

Charge controller operations : PWM VS Advance CC

:

29

Charge controller operations

• The temperature Compensation is a feature of CC that automatically adjusts charge regulation voltage for battery temperature changes.

• The sensors can be internal or may be fixed to batteries.

• Temperature compensation is recommended for all types of sealed batteries, which are more sensitive to overcharging than flooded type.

• Temperature compensation Helps to fully charge a battery during colder conditions, and helps protect it from Overcharge and Over discharge.

• For larger systems, the O/p of multiple CC may be connected in parallel and used to charge a single battery bank.

• A diversionary CC diverts excess PV array power to Auxiliary loads when primary battery is fully charges.

(96)

Maximum power point tracking (MPPT)

• A MPPT Charge controller operates PV arrays at Maximum power under all operating conditions independent of battery voltage.

• MPPT can improve array utilization and allow non-stnadard and higher array operating voltages, requiring smaller conductors and fewer source circuit to charge lower voltage battery bank.

• Normally the O/p current of a MPPT will be less than or equal to the I/p Current.

• If a MPPT CCU is used it is important to consult the Manufacturer’s spec to determine the Maximum O/p load.

31

(97)

Parallel connections

33

PV Inverter

Stand Alone inverter: operates from battery and supply power independent of the electrical utility system. They may also include battery charger to operate from an independent AC source such as generator.

Bi-m odal inverter: battery based interactive inverter acts as diversionary charge controllers by producing AC power o/p to regulate PV array battery charging and sends excess power to the grid when energized.

(98)

PV Inverter

Utility-interactive or grid connected inverter: operates from PV arrays an supply pow er in parallel w ith an electrical production and distribution network.

Types:

1. Module level inverter: They include AC modules and micro inverters. They are sm all and rated for 200 to 300W m aximum. Advantages of these inverters are, they include individual m odule MPPT and better energy harvest from partially shaded and m ulti directional arrays. More safer than string inverters as the m axim um dc voltage on array is for a single module (35 -60V).

2. String Inverter: small inverters in the 1 KW to 12 KW size range, intended for residential and small commercial applications. Generally single phase and lim ited to 1 to 6 parallel connected source circuits.

35

Different types of Grid interactive inverters.

(99)

Specification of inverters

37

(100)

Review Wiring and conduit size calculations

Determine circuit current :

PV Power S ource Maximum circuit current :

Inverter output circuit current :

39

Calculate required ampacity of the conductor (Wire)

The required ampacity of conductors is based on : • Maximum Circuit current

• Size of overcurrent protection device • Ambient temperature of the conductor • Type of conductor and insulation • The conduit fill of the conductor

(101)

(102)

(103)

Calculate Voltage Drop

45

(104)

47

(105)

 PV string cables, PV array cables and PV DC main cables shall be selected and erected so as to minimize the risk of earth faults and short-circuits.

 Wire Management: Array conductors are neatly and professionally held in

place

 Wiring systems shall withstand the expected external influences such as

wind, ice formation, temperature and solar radiation.

49

Install Wiring systems

 Protection by use of class II or equivalent

insulation should preferably be adopted on the

DC side

.

Common Installation Mistakes with Wire Management:

1. Not enough supports to properly control cable. 2. Conductors touching roof or other abrasive

surfaces exposing them to physical damage. 3. Conductors not supported within 12 inches of

boxes or fittings.

4. Not supporting raceways at proper intervals. 5. Multiple cables entering a single conductor cable

gland (aka cord grip)

5. Pulling cable ties too tight or leaving them too loose.

6. Bending conductors too close to connectors. 7. Bending cable tighter than allowable bending

(106)

Install Grounding system

51

(107)

Installing Mechanical Components

53

(108)

Install PV modules

55

(109)

Install PV modules

57

(110)

Visual Inspection

59

(111)

(112)

IEC 62446: Grid Connected Photo Voltaic Systems – Minimum Requirements for System Documentation, Commissioning Tests and Inspection

Learning Objective

.

commissioning tests

inspection criteria documentation

To verify the safe installation and correct

operation of grid connected solar Power

(113)

Content

Clause 4: System documentation requirements Clause 4.2: System Data

Clause 4.3: Wiring diagram Clause 4.4: Datasheets

Clause 4.5: Mechanical design information Clause 4.6: Operation and maintenance information Clause 4.7: Test results and commissioning data Clause 5 :Verification

Clause 5.2:Inspection Clause 5.2: Testing

Clause 5.2: Verification reports

3

Clause 4: System

(114)

5

4.2 System data - Basic system information

Project identification reference (where applicable)

.

Rated system power (kW DC or kVA AC).

PV modules and inverters - manufacturer, model and quantity.

Installation date.

Commissioning date.

Customer name

.

Site address.

(115)

4.2.2 System designer information

Information shall be provided for all bodies responsible for the design of the system. Where more than one company has responsibility for the design of the system, information's together with a description of their role in the project.

7 System designer,

company.

System designer, contact person. System designer, postal address, telephone number and e-mail address.

4.2.3 System installer information

Information shall be provided for all bodies responsible for the installation of the system. Where more than one company has responsibility for the installation of the system, information should be provided for all companies together with a description of their role in the project.

System installer, company

System installer, contact person. System installer, postal address, telephone number and e-mail address.

(116)

4.3 Wiring diagram

9 Array - general specifications PV string information Array electrical details Earthing and overvoltage protection a) Module type(s) b) T otal number of modules c) Number of strings d) Modules per string a) String cable specifications – size and type. b) String over-current protective device specifications c) Blocking diode type (if relevant).

a) Array main cable specifications – size and type. b) Array junction box locations c) DC isolator type, location and rating d) Array over-current protective devices – type, location and rating (voltage / current). a) Details of all earth / bonding conductors b) Details of any connections to an existing Lightning Protection System (LPS). c) Details of any surge protection device installed (both on AC and DC lines) to include location, type and rating. AC system a) AC isolator location, type and rating. b) AC overcurrent protective device location, type and rating. c) Residual current device location, type and rating (where fitted).

(117)

4.4 Datasheets

Datasheets shall be provided for the following system components NOTE The provision of datasheets for other significant system

components should also be considered.

11

Module datasheet for all types of

modules used in the system - to

the requirements of IEC 61730-1.

Inverter datasheet for all types of

inverters used in the system.

4.5 Mechanical design information

(118)

4.6 Operation and maintenance information

Operation and maintenance information shall be provided and shall

include, as a minimum, the following items:

13 Procedures f or v erif ying correct sy stem operation. A checklist of what to do in case of a sy stem f ailure. Emergency shutdown / isolation procedures Maintenance and cleaning recommendat ions (if any).

Considerations for any future building works related to the PV array (e.g. roof works). Warranty documentation for PV modules and inverters - to include starting date of warranty and period of warranty. Warranty Documentation on any applicable workmanship or weather-tightness warranties.

Clause 5 : Verification

(119)

5.3 Inspection (Requirements)

 PV array design and installation

 PV system - protection against overvoltage / electric

shock

 PV system - AC circuit special considerations

 PV system - labelling and identification

 PV system - general installation (mechanical)

15

PV array design and

installation.

(120)

Stand Alone SPV power Plant

17

(121)

Field Inspection Checklist for Array:

1. Number of PV modules and model number matches plans and spec

sheets

2. with the module model number and quantity of modules confirmed, the

physical layout of the array should match the supplied site plan. Common Installation Mistakes with Array Modules and Configurations: 1. Changing the array wiring layout without changing the submitted electrical

diagram.

2. Changing the module type or manufacturer as a result of supply issues. 3. Exceeding the inverter or module voltage due to improper array design. 4. Putting too few modules in series for proper operation of the inverter during

high summer array temperatures.

19

Ratings for DC Components

• DC components rated for current and voltage maxima (Voc stc corrected for local temperature range and module type; current at Isc @ stc × 1.25

Note:

1) Overload protection may be omitted to PV string and PV array cables when the continuous current-carrying capacity of the cable is equal to or greater than 1,25 times ISC STC at any location. 2) Overload protection may be omitted to the PV main cable if the

continuous current-carrying capacity is equal to or greater than 1,25 times ISC STC of the PV generator.

(122)

Array Junction Box/ Main Junction Box/Combiner Box

21

Fuse

Surge Protector DC Disconnect device

Incoming String Wires (L+ & L-) going to

inverter

Wiring systems

 PV string cables, PV array cables and PV DC main cables shall be

selected and erected so as to minimize the risk of earth faults and short-circuits.

 Wire Management: Array conductors are neatly and professionally held in

place

 Wiring systems shall withstand the expected external influences such as

(123)

DC Cables.

 Protection by use of class II or equivalent

insulation should preferably be adopted on the

DC side

.

Common Installation Mistakes with Wire Management:

1. Not enough supports to properly control cable. 2. Conductors touching roof or other abrasive

surfaces exposing them to physical damage. 3. Conductors not supported within 12 inches of

boxes or fittings.

4. Not supporting raceways at proper intervals. 5. Multiple cables entering a single conductor cable

gland (aka cord grip)

5. Pulling cable ties too tight or leaving them too loose.

6. Bending conductors too close to connectors. 7. Bending cable tighter than allowable bending

radius.

8. Plug connectors on non--‐locking connectors not fully engaged

23

DC Conductors earthing.

 Earthing of one of the live conductors of the DC

side is permitted, but there must be a simple

separation between the AC side and DC side.

(124)

DC switch disconnector

 In every PV installation it is

necessary to isolate the

photovoltaic panel from the

rest of the system.

 DC Isolators must have a

higher performance than the

traditional AC Isolators

because breaking direct

current is more difficult than

breaking alternating current.

 DC switch disconnector

should be fitted to the DC side

of the inverter.

25

415V, 63A, 3pole AC MCB

Example to calculate the disconnect devices

• Example of PV sizing of disconnect switches.

Determine the minimum size in terms of Voltage and current of the disconnect based on follow ing informations:

Maximum input operating range : 300 -480 V dc Maximum input voltage (Voc) : 600V

Maximum rated input current : 800A (DC)

Maximum input Isc rating : 1200 A (DC)

(125)

Example to calculate the disconnect devices

Solution :

• PV Disconnect

Maximum continuous input current = maximum input short circuit current rating * 125%

= 1200A * 125% = 1500A (DC) Maximum input Voltage (Voc) = 600 V (DC)

 The PV disconnect switch must be rated for minimum of 1500A (dc) @ 600 V (dc).

PV Installer Program-Participant Guide

Introduction to Solar Energy

Solar Energy

An in-exhaustible source of Energy

which God has bestowed on us

Solar Energy is a Electro Magnetic

Wave Radiation

Electro Magnetic Wave Radiation

• Gamma Rays 10

to 10

µ m

• X – rays 10

to 10

µ m

• Ultraviolet 10

to 1 µ m

• Visible Spectrum 0.38 to 0.78 µ m

• Thermal Radiation – near infrared and far infrared 1 to 10

µ

m

Position of the Sun

Solar Path Diagram

Horizontal & Vertical Shadow

Solar Radiation

Photovoltaic

Physics of Photovoltaic Generation

How PV Cell produce Electricity:

Solar PV Markets Capacity installed in 2011

PV Module Production, Supply, and Demand

Metrics

22

Performance rating

Inspection

Plan of

Civil Foundations

for Solar Power Plants

Contents:

Introduction to Soil

types for Foundations

Soil Map of INDIA:

What is Soil?

Mineral

45%

Air

25%

Water

25%

Organics

5%

GRAVEL

SAND

Clay

Silt

Minerals

Soil Groups

Estimated Soil Load Bearing Capacities

Sand and gravel –

Best

Medium to hard clays –

Good

Soft clay and silt –

Poor

Organic silts and clays –

Undesirable

Peat –

No Good / Avoid

Soil Strength Classification for Foundations

Laboratory tests for Soil

Soil Samples

Introduction to Foundations

Forces acting onto Foundation

Classification of Foundations

Shallow Foundations

Deep Foundations

D

B

Footing

P

Shallow Foundation

Pile

_{to 10}

_{µ m}

_{to 10}

_{µ m}

_{to 1 µ m}

_µ

_Silt

**OSHA* Safety Categories**