Commissioning and Documentation for proper Handover ... · PDF fileCommissioning and Documentation for proper Handover, Financing and Insurance Frank Zimmermann, 10 October 2014

Commissioning and Documentation

for proper Handover, Financing and Insurance

Frank Zimmermann, 10 October 2014

page 2

Commissioning and Documentation for proper Handover, Financing and Insurance

Summary

Content

• Introduction to ILF Group

• ILF – Renewable Energy Sector

• ILF – Selected PV References

• ILF – PV Software

• Commissioning and Testing

• System Monitoring

• Safety

• Documentation

• Financability and Insurability through Quality



Introduction to ILF Group

page 3

page 4

The companies

• Established by Mr. P. Lässer in 1967,

In 1969 Mr. A. Feizlmayr joined the company „ILF“

• Leading international, independent engineering and consulting

firms (100% privately owned)

• Completely independent with no affiliation to construction companies,

suppliers or financial institutions optimized project solutions tailored

to the client’s needs

• Interdisciplinary engineering and management services for complex

industrial and infrastructure projects (“one stop shopping“)

• Striving for market leadership through quality

• Safety, occupational health and environmental compatibility are of

highest importance

ILF Innsbruck

ILF München


Introduction of ILF Group

Business areas

Production facilities for oil and gas

Pipeline systems

Tank farms and underground

storage facilities

Refineries and petrochemical

plants

Airports

Roads

Railway systems

Tunnels and caverns

Buildings and structures

Alpine engineering

Water supply

Wastewater treatment and

disposal

Waste treatment and disposal

Hydropower, dam and

river engineering

Thermal power plants

Sea water desalination plants

Renewable energy

Climate protection

Electric transmission and distribution

systems

Oil & Gas

Energy & Climate Protection

Water & Environment

Transport & Structures

page 5



SPECIAL SERVICES

DESIGN AND

PLANNING

Preliminary

planning

Conceptual design

Permit application

design

Construction design

CONSULTANCY

Lenders Engineer

Due Diligence

Master plan

Feasibility study

Economic feasibility

study

PROCUREMENT

Tendering

procedure

Award of contract

Material

procurement

CONSTRUCTION

SUPERVISION

Quality surveying As-built

documentation

Construction cost tracking

START-UP

Personnel training

Operation manual

Maintenance manual

PROJECT MANAGEMENT

Integrated Consulting and Planning Expertise

• Geology and Hydrogeology

• Geotechnical engineering and

soil mechanics management

• Urban and environmental planning

and institutional strengthening

•Design of load-bearing structures

•Information management and GIS

•Automation and SCADA

•Project development

•Telecommunications

•Safety and risk

•Financial analysis

page 6





ILF – Renewable Energy Sector

page 7

Main Focus in Renewable Energy Sector

Thermal power plants

Sea water desalination plants

Renewable energy

Climate protection

Transmission and distribution

systems

Hydropower Photovoltaic CSP Waste to Energy Energy Efficiency

Energy & Climate Protection

page 8


Introduction of ILF Group – Renewable Energy Sector

page 9

Services

• Pre-feasibility assessment

• Feasibility studies

• Project appraisals

• Lender´s engineering

• Due diligences

• Project management

• Permit application design & land acquisition

• Planning & design

• EPC contracting

• Construction supervision

• Plant commissioning

• Acceptance tests

• Performance ratio verification

• Yield assessments

• 3D visualisations



page 10



Dipl.-Ing. MBA Frank Zimmermann

Education

1997 – 2002 Sales: Wholesale and Consumer

Sales- and Projectengineer

Export Manager, Fürth, de

2002 – 2005 Export Manager, Wuxi, cn

2005 – 2009 Managing Director, Singapore, sg

2009 - 2014 Managing, Haslach i.K., de

since 2014 Business Development Manager SE Asia

Project Engineer Photovoltaics

Bangkok, th

http://www.kit.edu/

page 11



Certified Expert for Photovoltaic Equipment (TUV)

Design Vetting, Evaluation of Offers

technically

economically

Risk Analysis

Feasibility Studies

Yield Assessment

Construction Supervision and Commissioning

Check of PV Plants:

I-U-curve for PV modules and entire plants

IR Measurement

EL Measurement

… for planned or already existing PV Plants

… in Crystalline or Thin Film Technology



ILF – Selected PV References

page 12

page 13

Selected References

• Photovoltaic Power Plant Dubai, UAE

PV power 13 MW, 33 kV grid connection

Status: built

Design Basis Report for 1 GW PV/CSP Power Plant

• Photovoltaic Power Plant Pakistan

PV power 100 MW

Owners Engineer, status: currently under construction

• Hybridization: PV-Diesel-Hybrid Power Plant

Al Yassat Island, UAE

Photovoltaics: 0,8 MW, 4 MW Diesel Generators

Owners Engineer, status: built

• Photovoltaic Power Plant El Salvador

PV power 17.8 MW, 46 kV grid connection

Status: built


Introduction of ILF Group – Selected PV References



ILF – PV Software

page 14

Software: Helios 3D ________

• Based on a DGM, the rows of tables are placed shadow-free (reference date)

automatically in the terrain

• Based on Auto CAD Civil 3D

• Data export to PVSyst

page 15


Introduction of ILF Group – PV Software

Software: Meteonorm ________

• Highest accuracy

• 1,325 meteorological stations with irradioation

measurements

• 8,325 meteorological stations

• 5 geostationary satellites

page 16



Software: PVSyst 6.2.6

• Simulation program for yield assessments

• Determination of specific yield and PR

• Import of Helios 3D Data

• Calculation of near-shading losses

page 17



Software: PVSyst 6.2.6

page 18



Software: INSEL________

• Professional Simulation Software for experts

• Simulation of

• Solar insulation Data

• PV-modules

• Inverter batteries wind energy

• Pumping systems

• Solar thermal power stations

• … and its combination

page 19





Commissioning,

Testing and Documentation

page 20

Commissioning through standarized System – Advantages

• „PV Plant Pass“ (PV Anlagenpass) or RAL seal-of-quality

• Advantages (PV Plant Pass):

• Installer proves installation according to good engineering practice

• Checklist, if installer did all neccessary works

• Complete documentation of the PV plant

• Insurances may provide cheaper rates

• Obtaining financing may be easier

• If problem occurs, detection of e.g. strings is easier

page 21


Commissioning and Testing

Commissioning through standarized System – Documentation

• „PV Plant Pass“ (PV Anlagenpass) or RAL seal-of-quality

• Documentation includes:

• Which components are used

• Which certificates have the components

• Which Warranties have the components

• Which norms have been applied during planning and installation

• How is the plant connected

• Plant was commissioned in „perfect shape“

page 22



Pass

• Summary of Plant

• Location

• Ownership

• Installer

• Commissioning-date

• Yield assessment

• Incl. seal

page 23



Components

• PV Modules: Manufacturer, electrical properties, certificates, warranties

• Inverter: Manufacturer, electrical properties, certificates, warranties

• DC Disconnector: Manufacturer, electrical properties, warranties

• Cables: Manufacturer, diameter, DC-string, DC-main, AC

• Mounting Structure: manufactuerer, certificates, type of system, static calculation

page 24



Information: Planning and Installation

• System configuration of PV plant: strings, arrays, installation

• System configuration of Installation: design, Overvoltage protection, theft protection

page 25



Test Reports

• Inspection Documents

• Inspection construction, installation, visit to plant

• Inspection document of electrical test of PV array

• Inspection document for electrical test of AC side

page 26



Test Reports (cont.)

• DC:

• Parameters: UOC @ STC, ISC @ STC

• Measurements: fuses, UOC, ISC, actual insolation

• Isolation Resistance: positive, negative

• AC:

• Inspect

• Probe

• Measure: R ISO, Earthing Resistance …

page 27



Certificates and Appendixes

• Attached documents:

• Electrical plan

• Roof-plan

• Modules: datasheet, warranty, certificates, list of S/N

• Inverter: datasheet, warranty, certificates, list of S/N

• DC switch/string box: datasheet, warranty, S/N

• Mounting system: data sheet, static

• Calculation of yield

• Technical documentation of monitoring system

page 28





System Monitoring

page 29

Monitoring

• Online or remote ?

• Bluetooth, RS 485, Ethernet, etc.

• Internet, GPRS, etc.

• Solar Sensor (global and array)

• Wind Sensor

• Temperature sensor

• Datalogging:

• Internet Portal

• Local PC

page 30


System Monitoring

page 31


System Monitoring

General Monitoring Diagram for Large Power Plants

• Fiber optic rings connecting inverters and transformer stations

• Location of sensor units

• Type and specs of monitoring cables

• Monitoring devices in inverters and transformer stations

• Monitoring situation from combiner box

• Data transmission via satellite, UMTS, GSM, etc



Safety

page 32

General Electrical Safety Rules

• Do not work alone

• Keep workspace clear

• Be alerted

• Be skeptical

• Be patient

• Expect the unexpected

• Never assume anything

page 33


Safety

Equipment Failures: Modules

• Cell Short Circuit

• Cell Open Circuit

• Interconnect Open Circuit

• Open circuit

• Short Circuit

• Glass Breakage

• Delamination

• Hot spot (Reverse-Biased)

• DC Arc Fault

• By-Pass Diode

• Encapsulant

• Bonding Path Resistance

• Reverse Current Overload

• Corrosion

• Strain Relief

• Insulation

page 34


Safety

Equipment Failures: Inverter

• Capacitor

• Bridge Circuit

• Insulation

• Output Overload

• DC Input Miss Wiring

• Ventilation

• Termination

• Component Short or Open Circuit

• Loss of Control Circuit

• Surge

• Harmonic

• Synchronization

• Overvoltage

• Ground Faultn

page 35


Safety

Equipment Failures: Inverter

• Capacitor

• Bridge Circuit

• Insulation

• Output Overload

• DC Input Miss Wiring

• Ventilation

• Termination

• Component Short or Open Circuit

• Loss of Control Circuit

• Surge

• Harmonic

• Synchronization

• Overvoltage

• Ground Faultn

page 36


Safety

Equipment Failures: Other

• Combiner

– Insulation

– Loss of Control Circuit

– Termination

– Undersized Bus

• Disconnecting Means

– Undersized

– Insulation

– Inadequate Withstand Current

• Overcurrent Protective Devices

– Undersized

– Inadequate Interrupting Capacity

• Connectors

– Inadequate Voltage Rating

– Lockable vs. non-lockable

– Make first break last ground pin in multi-pin connectors (plug)

page 37


Safety

Equipment Failures: Remedies

• Use appropriate overcurrent protective device type and rating.

• Assure that the maximum open circuit voltage does not exceed the equipment voltage rating.

• Assure that the maximum modules short circuit current does not exceed the inverter maximum input short circuit

current rating.

• Equipment are listed by a recognized testing agency according to approved test standards and labeled or

identified as listed.

page 38


Safety

Equipment Failures: Wiring

• Short-Circuit

• Ground-Fault Current

• Ground-Fault Voltage

• Excessive DC Open-Circuit Voltage

• Open-Circuit

• Overload

• Over Heat (i.e., ambient, solar radiation, harmonics, irradiance factor, etc.)

• Lack of, Improper or Inadequate Grounding (Equipment or System)

• Undersized Raceway

• Improper Terminations

• Improper connector

• Intermix of Dissimilar Metals (i.e., Cu and Al)

• Improper Binding Screws or Splicing Devices

• Improper Expansion Joints

• Rodents

page 39


Safety

Equipment Failures: Wiring Remedies

• Use Wire size suitable for the short circuit current of modules including the irradiance factor and solar exposure

de-rating effect.

• Use appropriate type and rated overcurrent protective devices.

• Include the effect of continues operation of the system and the ambient temperature.

• Coordinate terminal temperature ratings of various equipment terminals with that of wiring insulation.

• Use wiring insulation that is suitable for the exposed environments (wet, UV, corrosive, etc.).

• Assure wire stranding is compatible with wiring termination (i.e., fine strand vs. standard strand).

• Do not intermix different wiring materials (CU vs. AL).

• Provide properly sized equipment grounding that is based on circuit overcurrent protective device rating and

terminates into a fitting that is rated and sized appropriately

page 40


Safety

Equipment Failures: Wiring Remedies (cont.)

• Provide properly sized system grounding electrode conductor for grounded system that is based on PV source

ungrounded (energized) conductors.

• With some exceptions, provide dc GFP for PV system. The GFP must be sized based on KW rating of the system

by the manufacturer or the design engineer.

• Be aware that the GFP does not protect against electric shock hazard.

• Provide additional AC GFP when connecting to a service equipment or a feeder that has a GFP

• All PV system are required to have equipment grounding. Only a grounded system is required to have a system

grounding as well as an equipment grounding.

• Use properly sized raceway to avoid loss of insulation during installation.

• Limit the total number of bends in the raceway to no more than 360 deg.

• Adjust the wiring ampacity when more than three energized conductors are run in a raceway.

• Assure that the raceway is suitable for the environment encountered (i.e., temperature, physical strength, etc.).

page 41


Safety

Equipment Failures: Labels and Markings

• Due to inherent hazard of PV system and need for proper maintenance, numerous markings are required by listed

products and the electrical code.

• Labels and Markings may provide information on the components of the system, such as Module, PV system

operating condition, Identifying a component, Or a warning referring to possible shock hazard (i.e., upon activation

of GFP in a PV system or an open disconnect with both terminals still energized, etc.), Overvoltage, device ratings,

Presence of all sources, etc.

page 42


Safety

Rooftop

• Keep distances from roof sides (approx 1 m)

page 43


Safety

Rooftop

• Plan walkways in large installations

page 44


Safety



Financability and Insurability

through Quality

page 45

Overvoltage Protection

• Direct positive flash

• Direct negative flash

• Overvoltage from grid

• Coupling of electromagnetic interference

page 46


Financability and Insurability through Quality

Overvoltage Protection

• Direct positive flash

• Direct negative flash

• Overvoltage from grid

• Coupling of electromagnetic interference

page 47



Overvoltage protector

Static calculation

• Additional weight for rooftop

• Windload

• Snow ?

page 48



Insuranceability

• Use Certified Products:

• Solar Modules

• IEC 61215: crystalline modules

• IEC 61646: Thin film modules

• IEC 61730: Safety Standards (like UL, JET)

• Inverter

• DC Switches

• Cables

• Plugs

• Full documentation, incl. Static calculation

Issue a PV Plant Pass (full set of requirements)

page 49



Contact Details:

Frank Zimmermann Business Development Manager SE Asia

Project Manager Photovoltaics

ILF Consulting Engineers (Asia) Ltd.

Dr Gerhard Link Building, 12th floor

88 Krungthepkreetha Rd.

Huamark, Bangkapi, Bangkok 10240

THAILAND

www.ilf.com

mailto: [email protected]

Commissioning and Documentation of Large PV Power Plants

Thank You !