Generalised Technical Specifications for Grid Tie Solar Power plants

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Jasmin Gaines
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1 Generalised Technical Specifications for Grid Tie Solar Power plants The Grid tie Solar Power Plants without battery may be installed for any office buildings. As the office buildings have day time energy consumption, Solar System without battery is suggested, as the battery is the weak link in the system and requires regular maintenance as well as replacement in every 2-3 years. Also the efficiency of the battery based system is less due to loss in the battery (around 15%). The shadow free area required for installation of solar plant is appx 150 sq.feet (14 Sq.m) per KW. The Solar panels may be installed on the roof of the building. Sufficient area shall be available for servicing the system. The minimum clearance required from the parapet wall & in between row of panels is min 2 feet for cleaning the panels & servicing. In between the row of solar panels sufficient gap need to be provided to avoid falling of shadow of previous row on the next row. The Inverter /Power Conditioning Unit (PCU) shall be placed indoor in a safe and easily accessible place. The bench mark cost fixed by Ministry of New and Renewable Energy (MNRE) for Solar Power Plants without battery is as below: Upto 5 kwp Rs.160/Wp > 5 kwp to 100 kwp Rs.140/Wp MNRE provides 30% of the benchmark cost (or) 30% of actual cost whichever is less as capital subsidy for a maximum capacity of 100KWp per system. The details on how to decide the capacity of the solar system required for a particular building is enclosed as Annexure -I The detailed Technical Specifications, Standards & suggested Tender Eligibility Criteria are enclosed as Annexure IIA, IIB & IIC respectively.

2 ANNEXURE I Grid tie Solar Power Plant consists of following main components: 1. Solar Photo Voltaic (SPV) Array 2. Power Conditioning Unit (PCU) The SPV array & PCU may be sized as below: 1. Solar Photo Voltaic (SPV) Array The Capacity of the Solar Power Plant (Wp) ie., Wattage of the SPV array, required for a particular building, may be calculated in following 3 steps. The minimum of the 3 values may be taken as the capacity of plant. Step I: Capacity of Solar Plant (Wp) = 50% of the connected load of the building For example: Sl. Connected Wattage of Number of Total Connected No Loads each load (W) Load Load (W) (4 * 5) Tube Lights CFLs Fans Computers Printer Air Conditioner (1.5 ton split AC) Total Connected Load % of the Connected Load = 4090/2 =2045 W (Value I) Hence recommended capacity of Solar Plant in the building with total connected load of 4090 W is 2 KWp. Step II: Capacity of Solar Plant (Wp) may be such that it generates 25% of the energy requirement of connected loads in the building in a day. For example Sl. Connected Wattage of Number Total Connected Hours of Energy Required No Loads each load of Load Load (W) operation (Kwhr)* (W) (4 * 5) in a day (5*6) / Tube Lights CFLs Fans Computers Printer Air Conditioner (1.5 ton split AC) Total Energy Consumption in a day 34.7

3 25% of 35 Units = 8.75 Units 1 KWp Solar Plant generates approximately units a day. Hence 2 KWp (Value II) plant may be installed. Step III: Capacity of Solar Plant (Wp) may be such that, the maximum energy generated by the plant in an hour is 50% of the energy consumption of the building in an hour. Energy consumption during 10 am to 3 pm (good sunshine period) may be taken for this calculation. For example the energy consumption may be calculated as below: Date Energy meter Energy meter Difference Average consumption Hrs (3-2) in an hour in Units Hrs (4/(15 Hrs- 10 Hrs)) /5 = 2 50% of the energy consumption in an hour = 2/2 = 1 unit Hence 1 KWp (Value III) solar plant which generates maximum 1 Unit in an hour may be installed. The minimum among the 3 values is 1 KW. Hence 1 KW SPV array may be selected. 2. Power Conditioning Unit (PCU) The PCU / Inverter capacity, mentioned in KVA, shall be equal to SPV array capacity. Eg., 1 KWp PV array shall have PCU of 1 KVA capacity & 5 KWp PV array shall have PCU of 5 KVA capacity.

4 ANNEXURE-IIA TECHNICAL SPECIFICATION FOR GRID TIE SPV POWER PLANTS Solar PV Array (KWp) Power Conditioning Unit (KVA) To be filled based on the capacity of plant ---- do----- DEFINITION A Grid Tie Solar Photo Voltaic (SPV) power plant consists of SPV array, Module Mounting Structure, Power Conditioning Unit (PCU) consisting Maximum Power Point Tracker (MPPT), Inverter, Controls & Protections, interconnect cables and switches. PV Array is mounted on a suitable structure. Grid tie SPV system is without battery and should be designed with necessary features to supplement the grid power during day time. Components and parts used in the SPV power plants including the PV modules, metallic structures, cables, junction box, switches, PCUs etc., should conform to the BIS or IEC or international specifications, wherever such specifications are available and applicable. I. Technical Specifications of Major Components of Solar PV Power Plant 1. Solar PV modules and array 2. Module mounting structure 3. Junction Boxes 4. Power Conditioning Unit 5. DC & AC Switches 6. Cables and installation accessories 7. Earthing and lightning protection 1. SOLAR PV MODULES AND ARRAY (i) Only indigenous modules shall be used in the project. Solar module shall be Crystalline (Mono/Poly) (or) Thin Film (or) Concentrator PV modules type. The peak power output of the PV Module shall be min 100Wp under STC. Module Voc shall be minimum 21V. The total array capacity shall not be less than KWp (to be filled based on the

5 capacity of the plant) and this shall be operating at the DC voltage of V (to be selected based on capacity of the plant). The power output of the PV module must be reported under standard test conditions (STC). I_V curve of the sample module should be submitted. (ii) The mechanical structure shall withstand gusts of wind / cyclonic wind up to 150km/hr from back side of the panel. (iii) The offered modules must conform to the latest edition of any of the following IEC/ equivalent BIS Standards for PV module design qualification and type approval: Crystalline Silicon Terrestrial PV Modules : IEC 61215/IS14286 Thin Film Terrestrial PV Modules : IEC 61646/ Equivalent IS (Under Dev.) Concentrator PV Modules & Assemblies : IEC (iv) (v) (vi) (vii) In addition, the modules must conform to IEC requirements for construction & Part 2 requirements for testing, for safety qualification or Equivalent IS ( Under Dev.) PV modules must also qualify Salt Mist Corrosion Testing as per IEC 61701/IS SPV modules shall be certified by NABL/IECQ accredited test centre. The bidder shall submit appropriate certificates. Protective devices against surges at the PV module shall be provided. Low voltage drop bypass diodes shall be provided. (viii) Module Junction box (weather proof), where the module terminals shall be interconnected and output taken, shall be designed for long life out door operation in harsh environment as per the relevant BIS specifications and protected against surges. It should have a provision for Opening for replacing the cable, if required. (ix) PV modules used in solar power plants must be warranted for output wattage, which should not be less than 90% at the end of 10 years and 80% at the end of 25 years.

6 (x) Each PV module must use a RF identification tag (RFID), which must contain the following information: a. Name of the manufacturer of PV Module b. Name of the manufacturer of Solar cells c. Unique Serial Number & Model No. of the module d. Month and year of the manufacture (separately for Solar cells and module) e. Country of origin ( separately for solar cells and module) f. I-V curve for the module g. Peak Wattage of the module,im, Vm and FF for the module h. Date and year of obtaining IEC PV module qualification certificate i. Name of the test lab issuing IEC certificate j. Other relevant information on traceability of solar cells and module as per ISO 9000 series RFID shall be mandatorily placed inside the module laminate. A distinctive serial number starting with NSM will be engraved on the frame of the module or screen printed on the tedlar sheet of the module. 1.1 ORIENTATION AND TILT OF PV MODULES Modules shall be North South oriented at the Tilt Angle of 11 o - 13 o 2. MOUNTING STRUCTURES The PV modules will be mounted on fixed metallic structures of adequate strength and appropriate design, which can withstand load of modules and high wind velocities up to 150 km per hour. The support structure used in the power plants will be hot dip Galvanized Iron (G.I). The Mounting Structure should have the following features: The modules support structure shall be Mild Steel /hot dipped Galvanized (atleast 120 micron) Iron for holding the PV modules. The size of angle iron should not be less than 50x50x5 mm. Each panel frame structure shall be so fabricated as to be grouted on roof on its legs. The legs of the structure shall be fixed and grouted in the PCC foundation column made with 1:2:4 cement concrete. The

7 foundation shall support SPV modules at a given orientation, absorb and transfer the mechanical loads to the ground properly and shall withstand maximum wind speed of 150 km/hr. All nuts and bolts should be made of good quality Stainless Steel. The structure should be designed to allow easy replacement of any module. The array structure shall be so designed that it will occupy minimum space without sacrificing the output from the SPV panels. The minimum clearance of the lowest part of the module structure and the developed ground level shall not be less than 500 mm. The minimum clearance required from the parapet wall of the roof & in between row of panels is min 2 feet for cleaning the panels & servicing. The bidder shall specify installation details of the PV modules and the support structures with appropriate diagrams and drawings. The work shall be carried out as per the designs approved by the procuring entity. 4. JUNCTION BOXES The junction boxes shall be dust proof, vermin and waterproof and made of FRP / Thermo Plastic. The terminals shall be connected to copper bus bar arrangement of proper sizes. The junction boxes shall have suitable cable entry points fitted with cable glands of appropriate sizes for both incoming and outgoing cables. Suitable markings shall be provided on the bus bar for easy identification and cable ferrules shall be fitted at the cable termination points for identification. Each main junction box shall be fitted with appropriate rating blocking diode. The junction boxes shall be of reputed make. 4. POWER CONDITIONING UNIT (PCU) As SPV array produce direct current electricity, it is necessary to convert this direct current into alternating current and adjust the voltage levels to match the grid voltage. Conversion shall be achieved using an electronic Inverter and the associated control and protection devices. All these components of the system are termed the Power Conditioning Unit (PCU). In addition, the PCU shall also house MPPT (Maximum Power Point Tracker), an interface between Solar PV array & the Inverter, to

8 maximize Solar PV array energy input into the System. PCU including MPPT & protection conform to IEC 61683/IS 61683, IEC (1,2,14,30)/Equivalent BIS Std., DETAILED SPECIFICATION Nominal DC Array 1) Input Voltage DC Array Input 2) Operating Voltage Type of Solar Charge 3) Controller 4) Switching device Continuous inverter 5) Output Rating 6) Output Wave Form Total 7) Distortion Harmonic To be filled up based on the capacity of PV plant DC Voltage of the PV array shall be suitable for the MPPT range of PCU -20% to +15% of the DC Array input voltage in Sl.No. 1 above MPPT Based Solar Charge Controller MOSFET/IGBT based Equal to capacity of PV plant. To be mentioned in KVA Pure Sine Wave Output < 3% with resistive load 8) Output Voltage % in case of 1phase PCU % in case of 3 phase PCU 9) Output Frequency 10) Power Factor 11) PCU efficiency 12) Idle Current 13) Regulation 14) Overload Features 15) Cooling Operating 16) temperature > Hz. ± 0.5 Hz. > 90% at nominal voltage & power < 4% of rated capacity Line regulation & Load regulation 2 % 150% for 1 minute Forced Air cooling, with temperature controlled cooling fan C

9 17) Relative Humidity 18) LED/LCD Display : Indications Data monitor and 19) display controls 95% Maximum Display shall indicate system functional parameters and protection functional indicator RS485, Ethernet OR RS232 connectivity 20) Protections 1) Input over voltage 2)Low/high frequency 3) Short circuit 4) Under/over output voltage 6)Grid Input under 5) Over Temperature voltage / over voltage with auto recovery 7) DC disconnect 8)DC reverse polarity device 9) Anti Islanding Protection as per the standard 21) Enclosure Protection 22) Safety 5. DC & AC Switches IP 21(for indoor) as per IEC IEC IEC Part 1 & 2 3. Galvanic Isolation at input & output through transformer a. DC SIDE (i) MCB of suitable rating shall be provided for connection and disconnection of array & PCU for maintenance purpose. (ii) Switches and Circuit Breakers on DC side shall be DC rated or they shall be sufficiently de-rated, if AC rated switches are used. b. AC SIDE MCB of suitable rating shall be provided for connection and disconnection of PCU & load 6. Cables and accessories All the cables shall be supplied conforming to IEC 60227/IS 694 & IEC 60502/IS 1554 shall be of 1.1 kv grade as per requirement. Only PVC copper cables shall be used. The size of the cables between array interconnections, array to junction boxes, junction box to PCU, PCU to

10 AC Distribution Box etc shall be so selected to keep the voltage drop and losses to the minimum. Permissible Wire Drop on DC side shall be <= 1% The bidder shall supply installation accessories, which are required to install and successfully commission the power plant. 7. Earthing and Lightning Protection: Earthing : The array structure of the PV yard shall be grounded properly using adequate number of earthing kits. All metal casing or shielding of the power plants shall be thoroughly grounded to ensure safety of the solar power plants. Lightning: The SPV power plants shall be provided with lightning &over voltage protection. The main aim in this protection shall be to reduce the over voltage to a tolerable value before it reaches the PV or other sub system components. The source of over voltage can be lightning, atmosphere disturbances etc 8. OPERATION AND MAINTENANCE MANUAL An Operation and Maintenance Manual, in English and Tamil, should be provided with the solar PV power plants. The following minimum details must be provided in the Manual: (a) About Photo Voltaic & PV Module (b) Clear instructions about mounting of PV module. (c) About electronics used in (d) DO's and DONT's, (e) (f) Clear instructions on regular maintenance and Trouble Shooting of the power plants. Name & address of the person or Centre to be contacted in case of failure or complaint.

11 ANNEXURE-IIC TENDER ELIGIBILITY CRITERIA The suggested Tender Eligibility Criteria are as follows: S.No Minimum Eligibility Criteria Proof to be submitted for fulfilling the Eligibility Criteria 1. a) Bidder shall be a Registered Company/ Certificate of Incorporation or Firm in existence for at least past One Registration shall be submitted. audited year. b) Consortium not exceeding three i. Certificate of Incorporation or partners. Each partner of the Consortium Registration of all the partners shall be a Registered Company / Firm in shall be submitted. existence for at least past one audited ii. Copy of consortium agreement year. shall be submitted (OR) A letter of intent to execute a consortium agreement in the event of a successful bid shall be signed by all the partners and submitted with the bid along with the copy of proposed Consortium Agreement. ii. In case of Consortium, all partners of the consortium shall be liable jointly and severally for the execution of the contract in accordance to the contract terms and a statement to this effect shall be included in the letter of intent. 2. The Bidder shall use only SPV modules Necessary Self undertaking letter shall manufactured in India be submitted 3. Bidder should have experience in Copy of Work Orders and installation of SPV power plants of 1 KW performance certificate for satisfactory & above and shall have installed at least function of power plants obtained 10% of the quantity tendered (Power from the agency issuing work order plants installed minimum 6 months prior to the date of bid submission will only be considered ) & these systems should be working satisfactorily. 4. PV Modules & PCU of the SPV system Copy of test certificates along with shall conform to the MNRE standards as reports shall be submitted. per clause

12 5. Bidder should not be blacklisted by any Necessary Undertaking letter should of the State or Central Government or be furnished. organizations of the State or Central Government as on date of submission of tender 6. Annual Turnover of the bidder shall be as A summarized sheet of turnover per the following. In case of consortium, certified by registered CA should be each consortium partner shall have 50% furnished of the average annual turnover as per criteria (2) or (3) & Prime bidder shall satisfy the criteria (1) : CRITERIA Tender Tender Tender Tender Tender <Rs.50 Rs.50L Rs.2- Rs.10- >Rs.25 L -2Cr. 10Cr. 25Cr. Cr Turnover in PV Field in the last financial year - Min. Min. Min. Min. (OR in the current financial year) Rs.25 Rs.1 Rs.5 Rs.10 L Cr. Cr. Cr. Average annual Turnover in the last two - Min. Min. - - financial years Rs.50 Rs.2 L Cr. Average annual Turnover in the last three Min. Min. financial Rs.10 Rs.25 Cr Cr. years

13 1. PV MODULES: ANNEXURE- IIB MINIMAL TECHNICAL REQUIREMENTS / STANDARDS 1.1 The PV modules must conform to the latest edition of any of the following IEC/equivalent BIS Standards for PV module design qualification and type approval: Crystalline Silicon Terrestrial PV Modules Thin Film Terrestrial PV Modules IEC / IS14286 IEC / Equivalent IS (Under Dev.) Concentrator PV Modules & Assemblies IEC In addition, the modules must conform to IEC Part 1-requirements for construction & Part 2 - requirements for testing, for safety qualification or Equivalent IS (Under Dev.) 1.3 PV modules to be used in a highly corrosive atmosphere (coastal areas,etc.) must qualify Salt Mist Corrosion Testing as per IEC / IS IDENTIFICATION AND TRACEABILITY Each PV module must use a RF identification tag (RFID), which must contain the following information: (i) Name of the manufacturer of PV Module (ii) Name of the Manufacturer of Solar cells (iii) Month and year of the manufacture (separately for solar cells and module) (iv) Country of origin (separately for solar cells and module) (v)i-v curve for the module (v) Peak Wattage, Im, Vm and FF for the module (vi) Unique Serial No and Model No of the module (vii) Date and year of obtaining IEC PV module qualification certificate (viii)name of the test lab issuing IEC certificate (ix) Other relevant information on traceability of solar cells and module as per ISO 9000 series. RFID shall be mandatorily placed inside the module laminate

14 1.5 AUTHORIZED TESTING LABORATORIES/ CENTERS PV modules must qualify (enclose test reports/ certificate from IEC/NABL accredited laboratory) as per r e l e v a n t IEC standard. Additionally the performance of PV modules at STC conditions must be tested and approved by one of the IEC / NABL Testing Laboratories including Solar Energy Centre. For small capacity P V modules upto 50Wp capacity S T C perform a n c e as above will be sufficient. However, qualification certificate from IEC/NABL accredited laboratory as per relevant standard for any of the higher wattage regular module should be accompanied with the STC report/ certificate Details of Test Labs are given in Annexure I. 1.6 WARRANTY PV modules used in solar power plants/ systems must be warranted for their output peak watt capacity, which should not be less than 90% at the end of 10 years and 80% at the end of 25 years. 2. BALANCE OF SYSTEM (BOS) ITEMS/ COMPONENTS: 2.1The BOS items / components of the SPV power plants/ systems deployed under the Mission must conform to the latest edition of IEC/ E quivalent BIS Standards/ MNRE specifications / as specified below: BOS Item / System Standard Description Applicable BIS /Equivalent IEC Standard Standard Number Power Conditioners/ Inverters**including MPPT and Protections Storage Batteries Efficiency Measurements Environmental Testing General Requirements & Methods of Testing Tubular Lead Acid / VRLA / GEL Capacity Test Charge/Discharge Efficiency Self-Discharge IEC / IS IEC (1, 2, 14, 30) / Equivalent BIS Std. As per relevant BIS Std.

15 Cables General Test and Measuring IEC / IS 694 Method PVC insulated cables for working voltage up to and IEC / IS 1554 (Pt. I & II) including 1100 V and UV resistant for outdoor installation Switches/Circuit General Requirements IEC part I,II, III / Breakers Connectors safety /Connectors IS Part I,II,III A.C. /D.C. EN Junction Boxes General Requirements IP 54(for outdoor)/ IP 21(for /Enclosures indoor) as per IEC 529 for Inverters/Charge Controllers/Luminaries **In case if the Charge controller is in-built in the inverter, no separate IEC test is required and must additionally conform to the relevant national/international Electrical Safety Standards wherever applicable 2.2 AUTHORIZED TESTING LABORATORIES/ CENTERS Test certificates / reports for the BoS items/ components can be from any of the NABL/ IEC Testing Laboratories or MNRE approved test centers. 2.3 WARRANTY The mechanical structures, electrical works including power conditioners/inverters/charge controllers/ maximum power point tracker units/distribution boards/digital meters/ switchgear/ storage batteries, etc. and overall workmanship of the SPV power plants/ systems must be warranted against any manufacturing/ design/ installation defects for a minimum period of 5 years.

16 Test centers for MNRE Off-Grid Programme Lighting Systems Inverter Charge Controller >100 W Lab/ Organizat PV Module as per Battery MNRE Environment ion Efficiency Environmental protections Environmental Specificatio al ns (Including (IEC61215up MNRE (upto (Including IP) (Including IP) IP) MNRE SEC to100w P) MNRE MNRE 10KVA) MNRE MNRE NABL MNRE STC Test NABL/ NABL/ ERTL Facility NABL/ NABL/ NABL/ NABL/ MNRE MNRE (east) MNRE MNRE MNRE Up to 1000AH MNRE MNRE NABL/ (IEC61215)u MNRE (up to nder ICEEE- 3KVA) NABL/ NABL/ ETDC CB, NABL/ NABL/ MNRE MNRE (B) IEC MNRE Up to 100 AH MNRE NABL/ (upto100w P) MNRE NABL NABL/ (up to MNRE 10KVA) NABL/ NABL/ CPRI NABL/ NABL/ No MNRE MNRE (B) MNRE Up to 500 AH MNRE NABL/ MNRE Only NABL NABL NABL Electronics (up to (up to ERTL (N) No No & luminaire 5KVA) 5KW) NABL

17 NABL NABL (IEC61215 IEC (up to (up to (except NABL NABL NABL Pt.II and IEC 6KVA) 6KW) UL (B) battery) No 61701) NABL upto400w P NABL NABL NABL (IEC61215 & (up to NABL NABL (up to NABL TUV Pt-II) 10KVA) NO No 10KW) Rhineland upto400w P NABL NABL NABL Only (up to (up to Electronics NABL NABL NABL 5KVA) 5KW) Inter Tek No & luminaire No NABL NABL NABL PDF to Word *Beyond 10KVA self certification by the manufactures is acceptable.

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