BEST PARCTICES IN SOLAR PHOTOVOLTAICS
Dr. O.S. SASTRY
DIRECTOR PV TESTING, SOLAR ENERGY CENTRE,
MINISTRY OF NEW AND RENEWABLE ENERGY,
GOVERNMENT OF INDIA
PH. 0124-2579213; Fax: 0124-2579207e.mail:
[email protected]
REQUIREMENTS OF BEST QUALITY PV SYSTEMS
• HIGH PERFORMANCE
• SAFETY
• LONG TERM RELIABILITY
• LIFE CYCLE COST (Rs./ kWh) ( GRID PARITY ?)
Best practices solar energy include ….
• Programme Planning
• Setting Targets (physical, performance and cost
reductions)
• Site specific and Need based PV Systems
• Use of Standards with Indicators
• Growth of Industry: through put & reliability
• Creation of high quality testing laboratories
• Adoption of latest developments in technology
JAWAHARLAL NEHRU NATIONAL SOLAR MISSION (JNNSM)
(TARGETS)
PHYSICAL:
20,000 MW Utility Grid
2000 MW Off- Grid.
100MW Roof –Top Installations
Lighting Systems for 20Million Houses
RELIABILITY & LIFE :
• 35 years for PV modules?
COST:
• Grid Parity by 2020
JAWAHARLAL NEHRU NATIONAL SOLAR MISSION (JNNSM)
(ACHIEVEMENTS)
PHYSICAL:
 1050 MW Utility Grid
 155 MW Off- Grid
(Including Roof-top, Lighting, pumps all Off-Grid Systems)
RELIABILITY & LIFE :
• 10% in 10 years and 15% in 20 years for PV modules
COST:
• Rs. 7- 9/ Wp
MAIN PV SYSTEMS / APPLICATIONS
• LIGHTING SYSTEMS
- PROTABLE, FIXED HOME LIGHT AND STREET LIGHTING
• PV POWER PACKS
- < 1kWp POWER PLANTS
• STAND ALONE POWER PLANTS
- 1kWp TO 25kWp POWER PLANTS, TELECOMM
• UTILITY SCALE (MW CAPACITY) GI POWER PLANTS
- 1MW TO 50MW GI POWER PLANTS
• PV WATER PUMPS
- ½ HP TO 5HP AC/DC SURFACE OR SUBMERSIBLE
• OTHER APPLICATIONS
- WATER PURIFIERS, GLOW SIGN DISPLAY,
PV STANDARDS ADOPTED FOR PV COMPONENTS AND SYSTEMS
PV Modules :
 STC PERFORMANCE
- IEC 60904-2 (I-V )
- IEC 60891 ( TEMP & INTENSITY CORRECTIONS)
 DESIGN QUALIFICATION
- IEC 61215 (MON & MULTI CRYSTALLINE SILICON)
-
IEC61646( THIN FILM)
IEC 62108( CONCENTRATOR)
 SAFETY
- IEC 61730 (ALL MODULES)
 SALT, MIST AND CORROSIVE
- IEC 61701
PV STANDARDS ADOPTED FOR PV COMPONENTS AND SYSTEMS
PV BoS SYSTEMS:
 EFFICIENCY / PERFORMANCE
- IEC 61683 (PCU)
- IEC 62093( CHARGE CONTROLLERS & MPPT
 ENVIRONMENTAL
- IEC 60068 2 (1,2,14, 30)
 STORAGE BATTERIES
- IEC 61427 (ALL TYPE BATTERIES)

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- IS 1651
- IS 13369
CABLES, SWITCH/ CIRCUIT BREAKERS/ CONNECTORS
IEC 60947 PART I,II & III
EN 50521
IEC 60189, IS 694, IS1554, IS/ IEC 69947
PV STANDARDS ADOPTED FOR PV COMPONENTS AND SYSTEMS
PV SYSTEMS :
 Jn. BOXES/ ENCLOSURES
- IEC 2208
- IP 65 / IP 21
 SPV SYSTEM DESIGN
- IEC 62124
 INSTALLATION PRACTICES
- IEC 60364
- IEC 61727
 NATIONAL ELECTRIC CODES (NEC)
INDICATORS MATTERS..
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PV MODULE STC EFFICIENCY
PV ARRAY AND SYSTEM EFFICIENCY
LIFE TIME ENERGY YIELDS (YL)
PERFORMANCE RATIO (PR)
CAPACITY UTILIZATION FACTOR (CUF)
LOSS OF LOAD PROBABILITY (LOLP)
LIFE CYCLE COST (Rs./ kWh) ( GRID PARITY ?)
JNNSM TARGET FOR DEGRADATION:
• <10% IN 10 YEARS and <15% IN 25 YEARS
PERFORMANCE INDICATORS OF PV ARRAYS
• YIELD FACTOR = Yf = (kWh/kWp) or (Hours)
Yf = E ( ENERGY OUTPUT)/ Po ( STC DC POWER)
• REFERENCE YIELD Units (Yr) in Hours or kWh/kW
Yr = H ( IN PLANE IRRADIANCE )/ G( 1000W/SQ .M)
• PERFORMANCE RATIO (PR) = Yf / Yr
PR is dimension less, Quantifies Effect of Losses
PR depends on site Temperature, Spectrum &
Technology
WHAT ARE OFF-GRID
PV SYSTEMS?
LIGHTING SYSTEMS
Components of lighting System
• PV MODULE 3Wp to 74Wp
• Storage Battery 12V, 4AH to 100AH
(Flood Lead Acid Tubular or VRLA)
• Loads: 5 to 13W CFLs OR 2W to 9 W LED
• Electronics:
- High Frequency Electronics ballast(87%)/ DC-DC converters (95%)
- Charge Controller
- Protections
- Indicators
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Structures
PV Lighting System Quality Performance (MNRE Specs)
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Conditioning of the System
On-Off Cycles (Endurance Test)
Electronic Efficiency Measurement
Charge Efficiency Measurement
Lumen and LUX Measurement
Uniformity of Light
Quality of Light out put (UV content, Speckle)
PERFORMANCE ASSESSMENT OF LIGHTING SYSTEMS
•Conditioning test
•Electronic efficiency test
•Charge discharge efficiency
measurement
•Protections test
•Lumen measurement
•LUX measurement
•Spectral distribution measurement
of LED
•Measurement of view angle
LED AND CFL PERFORMANCE
COMPARISON AND SYSTEM
REQUIREMENTS
Color recognition
SOX lamp
Green-Red LEDs
19
Residential street
Before 36W TL
16 lux (meter under the lamp at
street level)
Now 20W LED
8 lux under lamp
The Physiology
Scotopic
<0,01 cd/m²
Mesopic
|0,001 cd/m²
Photopic
3 cd/m² |
> 3cd/m²
21
SPV WATER PUMPING SYSTEMS
Quality Testing of PV Water Pumping System
TYPE OF PUMPS
 DC Surface (Centrifugal) Pumps
 DC/AC Submersible Pumps
 Float Pumps ?
SPECIFICATIONS
 IEC 62253 & 61702 AND MNES Performance Guidelines 2006-07
INSTRUMENTATION
 Deep Sump Well
 PV Array
 PV Array Testers
 Data Loggers with sensors
 Flow & Pressure Gauges/Meters
Main Quality Indicators
 Throughput - Liters/watt/day
 Average Wire to Water efficiency
 Peak Efficiency
WHAT ARE THE MAJOR CONCERNS ?
• MAIN PROBLEMS ARE :
- MATCHING OF PUMP AND PV ARRAY
- EFFICIENCY OF MOTOR AND PUMP
- PV ARRAY STRUCTURES
- PROTECTIONS ( DRY RUNNING, GROUNDING, DC SHOCK etc.)
BATTERY TESTING
Quality Assessment of Batteries
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IEC 61427
IS 1651, IS 13369,
JIS 8709
PERFORMANCE TESTS
- Capacity Test at C/10 or C/20 rate
- Shelf Life
- Cycle Life vs. DoD
- Charge Efficiency
- Temp. Coefficients fully computer
- Spill Proof Features
WHAT ARE THE MAJOR PROBLEMS ?
• MAIN PROBLEMS ARE :
- WRONG INSTALLATIONS (MODULE, STRUCTURE & CABLES)
- POOR COMPONENTS
 LOW WATTAGE MODULE AND BATTERY
 POOR DESIGNS,
 POOR ELECTRONICS
- SYSTEM SIZING PROBLEMS ? (CONNECTION OF ADDITIONAL LOADS)
TO ENSURE THE QUALITY OF SUPPLIED SYSTEMS:
• A THREE STEP APPROCH FOLLOWED BY IEC TO ENSURE QUALITY
- TESTING OF PROTO-TYPE
- QUALITY TEST DURING MANUFACTURING
- QUALITY TEST OF PRODUCT FROM THE MARKET
SPV POWER PLANTS
OFF-GRID PV POWER PLANTS
• Stand Alone
• Hybrid
COMPONENTS SPV POWER PLANTS
1.
2.
3.
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SPV Modules
Batteries
Inverters
Charge Controllers
Loads CFLs, Pumps, Motors, Refrigerators etc.
Structures
STANDARDS FOR STAND ALONE POWER PLANTS
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Standards for POWER PLANT Components ( PERFORMANCE, DESIGN QUALIFICATION AND
ENVIRONMENT)
- PV MODULE –IEC 61215, 61646, 62108
- BATTERY – BIS , IEC (NO QUALIFIED SUPPLIER?)
- INVERTER IEC-61683 ( VERY FEW INDIAN SUPPLIERS!!) ,
- CHARGE CONTROLLER& MPPT –IEC 62093
Design Verification
IEC - 62124
INSTALLATION AND SAFETY
IEC- 62548
IEC – 61173 (OVER VOLTAGE PROTECTION)
NATIONAL ELECTRIC CODE FOR SYSTEM AND EQUIPMENT GROUNDING
Performance Monitoring, DATA exchange
IEC – 61724
I-V CHARACTERISTICS OF PV ARRAY ON SITE MEASUREMENT
IEC- 61829
ENVIRONMENTAL TESTS STANDARDS FOR ELECTRONICS
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OPERATIONAL CONDITIONS DIVIDED IN TO FOUR GROUPS
- INDOOR CONDITIONED
- INDOOR UN-CONDITIONED
- OUTDOOR CONDITIONED
- OUT DOOR UN-CONDITIONED
• IEC STANDARDS
- 60068-2-1 (COLD TEST -10°C ±3°C FOR 2 HOURS)
- 60068-2-2 (DRY HEAT TEST 55°C ±2°C FOR 16 HOURS)
- 60068-2-14 ( TEMPERSTURE CYCLING -5°C TO 55°C ±3°C FOR 5 CYCLES)
- 60068-2-30 (DAMP HEAT STUDY STATE 25°C TO 40°C ±3°C AND 93% RH 12+12 Hrs,
2Cycles)
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IEC STANDARD FOR INGRESS PROTECTION (IP)
- IP 21 FOR HOME LIGHTS/ LANTERNS
- IP 54/ IP64 FOR STREET LIGHTS
PERFORMANCE TEST STANDARDS FOR INVERTERS
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IEC STANDARDS
- 61683
EFFICIENCY OF PERFORMANCE of STAND ALONE INVERTERS (at unity and .25PF)
- 10% LOAD
- 25% LOAD
- 50% Load
- 75% Load
- 90-100% Load
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- EFFICIENCY OF PERFORMANCE OF CHARGE CONTROLLER AND MPPT (
- IEC 62093 ( PERFORMANCE TEST, PROTECTIONS, etc.)
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INSTALLATION AND SAFETY FOR OFF-GRID SYSTEMS
- IEC 62548 ( SYSTEM VOLTAGE, GROUNDING, RATING OF CONTROL DEVICES, etc.)
ENVIRONMENTAL TEST STANDARDS INVERTERS,
CHARGE CONTROLLERS AND MPPTs
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OPERATIONAL CONDITIONS DIVIDED IN TO FOUR GROUPS
- INDOOR CONDITIONED
- INDOOR UN-CONDITIONED
- OUTDOOR CONDITIONED
- OUT DOOR UN-CONDITIONED
IEC STANDARDS
- 60068-2-1 (COLD TEST -10°C ±3°C FOR 2 HOURS)
- 60068-2-2 (DRY HEAT TEST 55°C ±2°C FOR 16 HOURS)
- 60068-2-14 ( TEMPERSTURE CYCLING -5°C TO 55°C ±3°C FOR 5 CYCLES)
- 60068-2-30 (DAMP HEAT STUDY STATE 25°C TO 40°C ±3°C AND 93% RH 12+12 Hrs, 2Cyc)
IEC STANDARD FOR INGRESS PROTECTION (IP)
- IP 21 FOR INDOOR INVERTERS ( IN -DOOR CONDITIONED)
Quality Checks Of PV Power Plants
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Standards/Specifications
IEC, & IEEE Standards
Inspection Criteria
Performance Indicators
Energy Yields ( Yi = kWh/kWp )
Performance Ratio (PR= Yi/ Rf)
LOLP
Plant capacity factor/ Plant Utility Factor
Instrumentations
Array Testers
Data Acquisition Systems (DAS)
Current Voltage Power Transducers
Battery SOC Testers
Loads
Data Contents of SPV Power Plant
WHAT ARE THE MAJOR QUALITY CONCERNS?
• MAIN PROBLEMS ARE :
- WRONG DESIGNS ( SELECTION OF PV ARRAY, BATTERY BANK, INVERTER & LOAD)
- BATTERY RELATED PROBLES ( REDUCED LIFE SPAN)
- POOR INSTALLATIONS
- GROUNDING ( SYSTEM, EQUIPMENT AND LIGHTNING ARRESTERS)
- SHADOWING
- CERTIFICATION OF COMPONENTS
- MATCHING OF PV ARRAYS, MPPT RANGE, BATTERY BANK & INVERTER
WHO ARE QUALIFIED TO CERTIFY?
WHAT ARE THE REQUIREMENTS FROM THE LABS?
• REQUIREMENTS ARE :
- NABL or EQUIVALENT ACCREDITATION
- PART OF THE REQUIRED TEST EQUIPMENT
- MANPOWER
- INDEPENDENT TEST LABORATORY PREFERRD
AUTHORISED TEST CENTRES IN INDIA
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SEC PV MODULES, BATTERY , LIGHTING SYSTEMS (PERFORMANCE ONLY), WATER
PUMPS & INVERTERS
• OATCs
ERTL (KOLKATA) – BATTERIES, LIGHTING SYSTEMS & INVERTERS
ETDC ( BANGALORE) – PV MODULES, BATTERIES AND INVERTERS
CPRI ( BANGALORE) - BATTERIES, LIGHTING SYSTEMS (CFL), INVERTERS
• ADDITIONAL CENTERS FOR PV MODULES
TUV AND UL BANGALORE
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ADDITIONAL CENTERS FOR BATTERIES
CECRI OR ANY OF THE NABL CERTIFIED
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NABL ACCREDITED ADDITIONAL CENTERS FOR IELECTRONICS , LIGHTING
SYSTEMS , NVERTERS & MPPTS
ETDC (Bangalore), UL, TUV, INTER TEK (Noida), ERTL (kolkata), ETDC Pune,
ETDC Maholi and ETDC (G)
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ALL TESTING LABS WITH NABL ACCREDITATION FOR ENVIRONMENTAL ,
MECHANICAL & IP TESTS ARE APPROVED
QUESTIONS ??
THANK YOU FOR YOUR ATTENTION!!