Detailed Project Report - TEDA

Table of Contents

A. Project Proposal Summary…………………………………………………………………2

B. System Description ( Battery Back Up System)…………………………………..3

C. 50KWp PV System Integration……………………………………………………………5

D. Bill of Materials………………………………………………………………………………….6

E. Photo Voltaic Modules……………………………………………………………………….8

F. Solar Power Conditioning Unit/Inverter……………………………………………..9

G. Typical Module Mounting Structure………………………………………………….12

H. Junction Box / Enclosures………………………………………………………………….13

I. PVC Cables ……………………………………………………………………………………….14

J. Battery Bank……………………………………………………………………………………..16

Detailed Project Report

Detailed Project Report 50 kWp

Solar Hybrid System

CUSTOMER : Chennai Industries,

Vellore

© This confidential document is copy right and the property of R M Solaar Pvt. Ltd. It must not be

copied (in whole or part) or used for manufacture or disclosed without prior consent of the company

Prepared by: SR

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A. Project Proposal Summary

Sr. No. Project Description Data

1 Customer Name Chennai Industries,

2 Project Location Vellore District. Tiruthani-682 313

3 System Type Solar-off-grid System (Battery Backup).

4 Installation Location Ground /Roof mounted

5 PV Array Capacity 50kWp

6 Inverter Capacity 50KW MPPT Charger with 50kVA Inverter( 3-phase

O/P)

7 Operation Mode First priority on Solar-Battery and Balance on Grid

(optional)

8 Battery Capacity 1000Ah, 240VDC LMLA type

9 Load to be use Light Loads

10 Daily Load-Hrs of Operation 25KW load for 4.5 Hours (100% in Solar), (Recommended)

With grid support, no. of hours can be extended


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B. System Description (Battery Back Up System):

Solar electricity is produced when Photons from the sun rays hit the Solar PV panel, and

electrons are generated in the Photovoltaic cells, leading to production of Direct Current

(DC). The energy generated by PV modules is stored in rechargeable batteries and this

energy is consumed as per the designed application.

The DC electricity from the panels or/and battery passes through DC distribution network to

a inverter, which converts the DC electricity into AC for Single/Three phase operation by

using state of the art technology with MOSFET/ IGBT methodology and fed through A/C

distribution system linked to the consumer load.

The Photovoltaic (PV) Battery Back system has mainly 4 components:

- The Crystalline Silicon PV Modules

- Module Mounting Structure

- Battery Bank

- Power Conditioning Unit (PCU)


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Modules: The indigenous Moser Baer - make, Solar Crystalline Silicon Modules will be used

for this system.

Battery Bank: 1000Ah/240V LMLA type battery proposed for this system, make

HBL/SBL/ROCKET/or equivalent

Power Conditioning Unit/Inverters: We propose to use Emerson/PPS/OPS make or

Equivalent inverter for this proposed PV system requirements.

The output of the strings will be connected to PCU’s. The PCU is has three functions, one is

MPPT charge controller part which is controlling battery charging from the Solar. Second

function is to convert DC Power into AC power and feeding into the Load. It is designed with

a high efficiency >90% with IGBT technology, It is delivering the max. Power generated

through solar modules in to battery or load due to its inbuilt feature of MPPT operations.

The PCU is having internal self protection in case of any hazards from either load side or

Grid supply. Also the PCU has inbuilt contactors/breakers with fuses for self protections.

The PCU is having in-built microprocessor based controls. The third function of Inverter is to

synchronize with the utility (grid) power (with respect to the Voltage and frequency of Grid)

when solar power is not less and battery is discharge condition. The inverter automatically

controls the power flow from all sources and feed un-interrupted power to load.

The 3-phase output of the inverter is connected to the dedicated load of the building via

ACDB panel.


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C. 50kWp PV System Integration:

The 50 KWp Crystalline-Silicon Solar Photovoltaic Power systems for this project comprise

the following major components and services.

• 10KWp Solar Array consisting of 204 no Moser Baer make C-Si PV modules of 245Wp

(+/-3%) each. No of modules will vary as per selection of module capacity

• Module mounting structures to mount the solar modules with special protection against

corrosion.

• A 50kVA, 415VAC, 50Hz. three phase power output type Inverter with 50kW MPPT

charger at 240VDC battery input.

• The hybrid (Battery backup) Inverters are designed for maximum efficiency, reliability,

and are equipped with advanced monitoring, control alarms, safety features and remote

monitoring features.

• Mounting hardware and system DC & AC cabling

• Project Management including, design, supply, installation & Commissioning of the PV

system.

• Project Management Documentation, various drawings of required mechanical, civil and

electrical.

Our emphasis on quality, throughout the organisation, ensures that all components are

mutually compatible and manufactured into a professionally engineered and integrated

power system, thus enhancing system reliability, performance and longevity.


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D. Bill of Material

Bill Of Material : 50 Kwp

Capacity Load : 25KW for 4.5Hrs

Chennai Industries, Vellore District. Tiruthani-682 313 Solar:Grid- 100:0

Sl.No Items Quantity Units Make

1 Solar Photo Voltaic Crystalline Module (245Wp,+/-2%) 204 Nos Moserbaer

2 Module Mounting Structure 1 Set Moserbaer

3 Array Juntion box 3 Nos Moserbaer

4 Main Junction box 2 Nos Moserbaer

5 1 Core 4.0 Sqmm Cu XLPE Cable 1000 Meters Siechem/Century/or

equivalent

6 2 Core 16 Sqmm Cu PVC Cable 75 Meters Siechem/Century/or

equivalent

7 1 Core 35 Sqmm Cu PVC Arm. Cable 200 Meters Siechem/Century/or

equivalent

8 1 Core 70 Sqmm CU PVC Cable 30 Meters Siechem/Century/or

equivalent

9 3.5 Core 35.0 sq.mm Alum. PVC Arm Cable 50 Meters Siechem/Century/or

equivalent

10 PCU : Solar Hybrid Type (50Kwp SCC,240V DC battery

Input, 50KVA 415V AC output) 1 No. Emerson/OPS or Equivalent

11 Battery Bank 1000Ah@240V(2V-1000Ah Cell x 120 Nos)

LMLA Type 1 Set HBL/SB or Equivalent

12 DC Distribution Board 1 No. Moserbaer/or equivalent

13 AC Distribution Board 1 No. Moserbaer/or equivalent

14 Super Earthing Kit 1 Set IBEX Super Earthing Kit

15 Lightning Arrestors & overvoltage protection 3 Set Standard Make

16 Installation Kit (Electrical Accessories) 1 Set

Terms and conditions.

1) Site preparation will be in scope of customer. In case any equipment on the rooftop is obstructing the installation of

modules, it will be in scope of customer to make the site ready for installation of the modules and associated

equipment

2) Standard Module Mounting Structure considered for Normal shadow free Plain RCC roof with Anchor bolt fasteners

sealing with Roof.

3) Moser Baer scope of cabling up to ACDB only, From ACDB to Load Distribution point is in customer scope

4) It is recommended to do a site survey before the final offer/order acknowledgement

5) The Bill of materials as considered above and the makes are indicative only .Due to continual improvement and

development the Rating and specifications of solar module, inverters (PCU) may change.


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System Schematic Diagram 50 KWp Solar Off-grid System

Dedicated Load should connect with the Solar system


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E. Photo Voltaic Modules:


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F. Solar Power Conditioning Unit/Inverter

The solar hybrid bi-directional inverter is most commonly used for battery backup system

and reliable for uninterrupted quality power supply to loads. Easy to install and operate. It

incorporates advanced maximum power point tracking technology to maximize the energy

harvested from a PV array. To minimize the power losses during the conversion process, the

inverter switching technology uses insulated gate bi-polar transistors (IGBT). It meets all

applicable European, CE requirements.

a. The efficiency of the PCU shall be at >92% full load.

b. The PCU shall have internal protection arrangement against any sustained fault in the

system to which it is connected.

c. Power conditioning unit will be three phase type and have static solid state components.

both AC & DC lines shall have suitably rated isolators to allow safe start up and shut

down of the system.

d. Typical technical features of the inverter shall be as follows:

Sr No Description Specifications/Details

1 INPUT

a) Array Input 50 kWp

2 CHARGE CONTROLLER

a) Type MPPT (Maximum Power Point Tracking) – 50 kW

b) DC Link Voltage Range 0 to 500 volts DC

c) MPPT Range 230 to 400 volts DC

3 BATTERY

a) Battery Voltage 240 VDC Nominal

b) Type LMLA type 2.00V 1000Ah Cell x 120 nos

4 INVERTER

a) Type IGBT Based with DSP Control

b) Power Capacity 50kVA, 415V,50Hz. 3-Phase output

c) Load Power Factor 0.8 Lag / 0.8 Lead

d) Nominal Voltage 415 V, 3- Phase, 50 Hz,

e) Regulation Nominal voltage can be adjusted by ±5% via system set

points

g) Frequency 50Hz +/-0.5% (Standalone mode)

Tracks grid frequency in the range of 50 +/-3Hz when

working in parallel with the grid


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Sr No Description Specifications/Details

h) Waveform Sinusoidal

i) Total Harmonic Distortion Less than 5%

j) Over Load Capacity 150% for 30 Sec

k) Switches Type Sinusoidal PWM based IGBT switching

l) Duty Continuous

5 EFFICIENCY

a) Inverter Efficiency (DC to AC) At 100 % load - 94%

At 50 % load - >90%

6 ENVIROMENTAL

a) Ambient Temperature 5 to 50 degC

b) Humidity 0 - 90% Non Condensing

7 PHYSICAL

a) Enclosure Protection Grade IP 20/IP30

b) Cooling Forced Cooling (Thermostatically Controlled)

c) LCD Display DC & AC parameters

d) Protection Inverter Over Load >150%

Inverter Short Circuit

Grid Over / Under Voltage, Frequency

Battery Over / Under Voltage

DC Input Reverse


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G. Typical Module Mounting Structure

MS Galvanized mounting structure as per the requirements of the project and to installed

maximum nos. of modules in min. area. The structure is designed in such a manner that

module can be replaced easily and in line with site requirements and it is easy to install and

service in feature.

Mounting Structure will support SPV modules at a given orientation, absorb and transfer the

mechanical loads to the ground properly and will not any requirement of welding or

complex machinery at site.

The structure is designed in such a way that it will take less space and will withstand wind

load up to 150kM/hr.

All fasteners, nut and bolts are made of Stainless steel - SS 304 5.4.6 PCC

FOUNDATION BASE: The legs of the structures made with GI angles are made of fixed and

grouted in the PCC foundation columns made with 1:2:4 cement concrete.


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H. Junction Box/Enclosures:

All Junction boxes/enclosures are IP65 (outdoor) and IP20/21 or equivalent (Indoor)

DC Distribution Board:


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AC Distribution Board:


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I. PVC Cables:

All the cables will be supplied conforming to Indian/international standard IS 694/IS

1554,IEC 60189,IS/IEC69947 & shall be of 650 V/ 1.1 kV grade as per Interconnections, array

to junction boxes, junction boxes to PCU etc will be so selected to keep the voltage drop

and losses to the minimum.

The bright annealed 99.97% pure bare copper conductors that offer low conductor

resistance, they result in lower heating thereby increase in life and savings in power

consumption. These wires are insulated with a special grade PVC compound formulated and

manufactured in-house. The skin coloration offers high insulation resistance and long life.

Working voltage Up to 1100V

Temperature range -15 deg C to +70 deg C

Sizes Suitable sizes

Color codes Red, Yellow, Blue, Black and Green (for earthing)

Technical Specifications for Cables

Parameters Specifications


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J. BATTERY BANK

The battery shall be LMLA type Battery.

S. No. Parameters 240V-1000 Ah (SPV_HR) Battery Details

01 Battery type Tubular Low Maintenance Lead Acid Battery

02 Battery rating 240Volts-1000AH(SPV - HR)

03 Model offered TS 1000 H

04 Cell dimensions (L x W x H) 418 ± 10 x 170 ± 10 x 688 ± 10 in mm

05

Cell Weight

a) Dry weight

b) Wet weight

56.6 ± 5% Kg.

80.8 ± 5% Kg.

06 Battery Dimensions (L x W x H) As per schematics.

07 Capacity 1000 Ah at 10 hour discharge rate to an end cell voltage of 1.80

Volts/cell at 27C

08 Number of cells 120 cells

09 Applicable standards IS 1651: 1991

10 Ampere hour efficiency > 90%

11 Watt hour efficiency > 80%

12 Self discharge < 1% per week at 27C

13 Designed Cycle life 1500 Cycles at 80% depth of discharge at 27°C

5000 Cycles at 20% depth of discharge at 27°C

14 Electrolyte required for first

filling Approx. 19.8 liters per cell of 1.22 Sp. Gr. Acid

15 Recommended initial charging

Starting rate = 90 Amps till cell voltage reaches to 2.4 V/cell. Then

continue charging at finishing rate.

Finishing rate = 45 Amps till the voltage reaches to 2.60-2.75 V/cell.

The charging shall be terminated when the voltage and specific gravity

reading is constant for 3 successive hourly readings.

16 Normal Recharging

Starting rate = 100 Amps till cell voltage reaches to 2.4 V/cell. Then

continue charging at finishing rate.

Finishing rate = 45 Amps till the voltage reaches to 2.60-2.75 V/cell.

The charging shall be terminated when the voltage and specific gravity

reading is constant for 3 successive hourly readings.

17 Boost charging Constant current of 125 Amps for a period of 10 to 12 hours. Voltage

of cell at end of full charge: 2.60 to 2.75 V

18 Trickle charging rates Min: 1000 milli amps; Max: 4000 milli amps

19 Storage period 2 years in dry and uncharged condition.


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20 Electrolyte specific gravity of

the filling at 27C 1.22 0.005

21 Electrolyte specific gravity at

the end of charge at 27C 1.24 0.005

22 Electrolyte specific gravity at

the end of discharge 1.17 (Approx.)

23 Material of battery container Hard Rubber

24 Type of Positive plate Tubular

25 Type of Negative plate Flat pasted

26 Terminals Lead alloys.

27 Material of Separator Sintered micro Porous Polyethylene ribbed separator

28 Electrolyte Sulphuric acid (H2SO4) conforming to IS 266

29 Supplied condition Dry and uncharged condition.

30 Sealing method Bitumen sealing

31 Type of Stands Wooden ( Sal wood / Teak wood )

32 Designed Float Life 15 years in float application at 27°C.

End of Proposal

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Detailed Project Report - TEDA