Implementation Framework for Enhancing Distributed Solar ...€¦ · 1. STAAD Pro Certification 2....
Transcript of Implementation Framework for Enhancing Distributed Solar ...€¦ · 1. STAAD Pro Certification 2....
Implementation Framework
for Enhancing Distributed
Solar PV Quality and
Safety for India
MNRE-USAID PACE-D 2.0 RE Program January 21, 2020
NREL | 2
Quality and
Safety Importance in DPV
On the field
3
Importance and Relevance of Quality and Safety aspects in DPV
Stakeholders’ Confidence
Utility Planning Revenue Loss to
Investors
Early Retirement of Systems and Disposal Woes
Accidents and Loss of Life
Key requirements for Quality & Safety Infratructure in DPV
Significant work at policy & regulation level; quality still one of the key concerns
MNRE
• List of Component Standards for all DPV
• Approved List of Models and Manufacturers
• Solar Pump Specifications announced in July 2019
SECI
• Model Tender Document for DPV
• Technical Specifications for Components and O&M Procedures
CEA
• Grid Connectivity Regulations
• Safety Regulations for DPV and Meters
SERCs
Technical Specifications in the Regulations
List of Standards for all components
SNA
• Adoption of MNRE guidelines and standards
• Independent Inspection Requirements (GEDA)
CEI
• Detailed procedures for SLD and actual installation approvals (Karnataka)
• Standard SLDs with all component specifications (Kerala)
Discom
• Meter Specifications based on Capacity and Consumer Type
SCGJ
Training and Certification of Discom Grid Engineers in various states & solar PV Entrepreneurs & Installers
Quality is a major challenge for the solar industry – which includes the
solar rooftop & distributed solar PV sector as well
Studies on Quality in India by PTB, UL and NISE say so………
• Pilot Study on Quality Aspects of PV Plants in India – By PI Berlin, September 2017
• All India Survey of Photovoltaic Module Reliability: 2014/16//18 – NCPRE, IIT Bombay & NISE
• UL Engineering challenge 2015 – Team 1
• UL Engineering challenge 2015 – Team 2
And these observations were reinforced through observations on the ground
Common findings from these Reports ….. and observed on ground
Solar Modules Quality -
varied quality from different/
same suppliers
Solar module
Performance Issues –
early degradation, micro-
cracks, PID, snail trails
Safety & Protections – Faulty
earthing, insufficient LPS, underrated
fuses and SPDs, disregard for fire
handling systems
Installation methods – partial
shadows on array, long runs of
DC cables, loose connections,
corrosion in structure
8
Commissioning – absence of independent inspection & lack
of commissioning tests
Performance – lower energy generation, intermittent
monitoring/ lack of timely follow up on corrective actions
O&M – inadequate maintenance, no schedule for
preventive maintenance
Documentation – absence of proper documents with customers,
planning/ design documents not shared with customers
NREL | 9
Methodology
of the Study
Methodology for the Study
Background research – Indian and Global
studies
Stakeholders Interviews
- In-person
- Telephonic
- Written responses
Explore Best Practices and
solutions in other countries
Derive possible solutions list with
their characteristics
Share and explore recommendations with stakeholders
Support implementation of
recommended solutions
NREL | 11
Study
Findings
t
The Distributed Solar PV Project Development Chain
Site Preparation
Erection of Structure
Wiring, Inverter & Safety
Module Installation
Commissioning O&M
Installation Stage
Design Quality (15%)
1. Fasteners (15%)
2. Handling of Modules (5%)
3. Earthing and Protections (5%)
4. Rest (10%)
The Distributed Solar PV Project Development Chain – 3 distinct phases -
surveys & literature show that each distinct phase has specific issues
1. Array Layout (7%)
2. String Inverter Mismatch (3%)
3. Access to Site (3%)
4. Rest (2%)
1. Modules (15%)
2. Structures (15%)
3. Junction Boxes (10%)
4. Rest (10%)
Components
Quality (50%)
Installation & O&M Quality (35%)
Issue definition Frequency Impact Respondent
(%)
Part or full shadow on the array throughout the year or some days of the year
H H 60
Inclined array on super structure or on sloping roofs looks aesthetically good but difficult to clean and maintain and repair
H M 75
Wrong enclosures of JB / SCB / DCDB / ACDB H H 70
Under specifications of protection devices like isolators, MCBs, MCCBs H H 60
Structure not able to withstand high wind pressure due to wrong material, loosely fixed members and modules, wrong design; not suitable for particular wind zone according to the standard
H H 90
Provision of insufficient (or nil) working space in form of walkways, railings, staircases, lifelines
H H 60
Inadequate earthing provision H M 80
Over estimation of energy H H 70
Over emphasis on capital cost H H 70
Key Findings - Design
Array layout to conforms to shadow analysis drawing – check drawing with actual layout
PV Syst/ PV Sol reports should be used to verify proper – on site matching – post installation check
1. Pathway next to array for R&M 2. Access to modules – without
specialised equipment 3. Provision of lifeline for safety
Array
Layout
(50%)
1
String
Inverter
Matching
(20%)
2
Site
Access
(10%)
3
Tests/ check points to address these key highlighted quality & safety issues problems
Design
Issue definition Frequency Impact Respondent (%)
Mild steel used for structure - rusting (even with anti rust paint)
H H 70
Galvanizing in GI not uniform, not of required thickness; leading to corrosion
H H 70
Low gap between ridge of the corrugated metal sheet roofing and module back surface; increase in module temperature
H H 60
Too thin structure components (angles, tubes, squares, C or I sections) resulting in warping and bending of structure
H M 70
Structure Certificate not submitted; Certificate is incomplete; Certificate does not serve the purpose
H M 70
Poor quality components (cells, EVA, backsheet, JB, etc.) used in module manufacturing
H M 90
Missing module certificates (or invalid / mismatching) H M 70
Key Findings - Components
• STAAD Pro Certification • Boundary layer wind tunnel test • Material treatment
• Bill of Materials • Acceptance Testing • Flash Test (At factory) • EL Test (At factory) • LID (At factory) • Visual Inspection (At factory) • Thermal Imaging (At site)
Integrate with Inverter or test all protection devices
Tests/ check points to address these key highlighted quality & safety issues problems
Components
Structures
(100%)
1
Modules
(50%)
2
Junction
Boxes
(100%)
3
Issue definition Frequency Impact Respondent
(%)
Lack of inspection by qualified and experienced engineer leaves many areas for improvement that cannot be rectified later
H H 90
Structure components, hardware and fixing to the roof H H 90
Walkways, railings, earth pits are not checked H M 90
CEIG / Discom inspection does not completely cover PV side aspects
H M 70
Handling of modules prone to accidents and unseen module damage
H M 60
Modules tightened at different torques producing stress on modules and exposing to damage under high wind conditions
H M 70
In O&M SPDs not periodically inspected to check if these have been sacrificed and need replacement
H M 60
Key Findings – Installation and O&M
Check fastener design with finite element analysis or similar
Thermal Imaging Test – and compare results with flash test
1. Lightening arrestors effective radius covering array
2. No. of Earthing's – Min. of 3 for each system
3. Soil Resistivity in each Earth pit < 5 Ohms
Tests/ check points to address these key highlighted quality & safety issues problems
Installation
Fasteners
(50%)
1
Handling
of Modules
(20%)
2
E&L
Protection
(100%)
3
These Quality & Safety issues are more commonly observed in
• 70% systems under Capex model
• 49% non-industrial customers
• Only 11 EPC players had market share higher than 1% of total 2018 market of 1,836 MW
Key factors behind low quality and unsafe solar PV systems in India
Huge focus on capital costs rather than
LCOE
Lack of knowledge
amongst EPC & installers – no
eligibility criteria
Customer ignorance
No push back on EPC due to
low quality work &
performance
Gaps in existing quality & safety
standards
Lack of proper inspection during and
after installation
Absence of mandatory
requirement of Supervision and Audit
NREL | 22
Potential
Solutions
NREL | 24
NREL has worked with the international community to help develop the IECRE system for certification, at each step of a PV system’s life.
Design
Qualification
Substantial Completion
Annual
Performance
Asset Transfer
Project Timeline
Technical standards Certificates for system
IECRE already issues certificates
Updated IEC technical standards feed into the new IECRE system.
OD 403, “Plant Design
Qualification Certificate”
OD 402, “Annual PV plant performance
certificate”
OD 401, “Conditional PV
project certificate”
OD 405-1, -2, -3 Module QMS
OD 410-1, -2, -3 QA for Installation and O&M
OD 404, “PV Plant
Assessment”
Learnings from US experience – NREL
Learnings from Australia experience – Clean Energy Council
Clean Energy Council - promotes awareness, thought leadership and regulation for clean energy
businesses in Australia. The regulation is provided through a system of endorsement and accreditation.
Accreditation is available to individual installers and designers.
• There are now around 4,500 Clean Energy Council accredited installers in Australia • Rigorous application process for accreditation, use of CEC approved products and
CEC compliance procedures
CEC Approved Solar Retailer -
1st stop for customers looking to buy solar from a certified company. These retailers are signatories to the CEC Solar Retailer Code of Conduct - designed to stamp out unethical practices in the industry including:
• Misleading claims & advertising regarding performance, size of solar PV system, government incentives, suitability of PV systems and future electricity bills;
• Not taking responsibility for the PV system including product warranties and workmanship;
• Sub-standard installation work; and • Retailers not taking responsibility for subcontracted parties acting on their
behalf
CEC Accreditation
Potential Recommendations
Information Database – Consumers
& Developers
Voluntary System and Installer Certification,
with Third-Party Inspection
Mandatory System and Installer Certification
Require Mandatory Third-Party Inspections
Update Guidelines from the MNRE
Create a Rating System of Developers Based on
their Quality and Performance Records
Create Guidelines for New EPC Companies
and Installers
3rd Party Module Quality Assurance
NREL | 27
Select
Recommendations
The Distributed Solar PV Project Development Chain – Path to Solution Set (1)
Pre-installation Stage Modules Every
Project
Installation (Pre-
commissioning) E&L
Protection Evaluate appropriateness
of Safety equipment(s) Agency concerned
with safety
Every Project
Site Access Evaluate Safe access/ lifeline to system
Agency concerned with safety
Every Project
Junction Boxes Evaluate Quality of Safety Equipment
Agency concerned with safety
Every Project
Structures Evaluate Quality of
Design Agency concerned
with safety Every
Project
Independent Technically Qualified Agency
Evaluate Quality of Input Material & Production
The Distributed Solar PV Project Development Chain – Path to Solution Set (2)
Post Commissioning
Array Layout Evaluate Array layout vis a vis
layout in shadow analysis Independent Technically
Qualified Agency Sample – Post Eval
String Inverter Matching
Evaluate String Current matches Inverter MPPT
Independent Technically Qualified Agency
Sample – Post Eval
Handling of Modules at Site/ Transport
Evaluate quality of modules at site – compare with Module tests analysis
Independent Technically Qualified Agency
Sample – Post Eval
Structures Structural Safety Independent Technically Qualified Agency
Sample – Post Eval
The Distributed Solar PV Project Development Chain – Key quality & safety issues &
potential solutions
Stage of Project
Development
Key Issue Potential Solutions
Design
Array Layout Array layout to conforms to shadow analysis drawing – check drawing
with actual layout
String Inverter
Matching
PV Syst/ PV Sol reports should be used to verify proper matching – on
site matching – post installation check
Site Access Pathway next to array for R&M; Access to modules – without
specialised equipment and Provision of lifeline for safety
Components
Structures 1. STAAD Pro Certification
2. Material treatment
Modules
• Bill of Materials
• Acceptance Testing
• Flash Test (At factory)
• EL Test (At factory)
• Visual Inspection (At factory)
• Thermal Imaging (At site)
Junction Boxes • Integrate with Inverter or test all protection devices
Installation E&L Protection
1. Lightening arrestors effective radius covering array
2. No. of Earthing's – Min. of 3 for each system
3. Soil Resistivity in each Earth pit < 5 Ohms
Handling of Modules 1. Thermal Imaging Test – and compare results with flash test
Electrical Safety
Assurance
Module Quality
Certification
Vendor Rating
NREL | 32
Select
Recommendations 1 –
Module Quality
Certification
Module
Quantitative
Data driven
Time based
The Distributed Solar PV Project Development Chain –
Basic Design Principles for Solution Sets
Basic Design
Principles
Performance Based
Modular
The Distributed Solar PV Project Development Chain – Implementation Framework for
Module Quality Assurance (1)
Why Module Quality Assurance: 1. Modules reported as one of the three main components with quality issues 2. Modules make up almost 50% of the cost of the system - impact of bad module quality can be loss of upto 50% of
project output 3. Module quality, even from same suppliers has shown variations
• Manufacturing in line inspection carried out by large project developers (by themselves or inspection agencies)
• 1st hand checking of Bill of Materials of Module • 1st hand checking of Module Component Quality (EVA
back-sheet, Cells, JB etc.) • Observation of in line tests – Flash & EL tests • Post sale warranty support available to large
developers due to large repeat orders
• Procurement through dealers and agents (sometimes not even authorised)
• Small order sizes – no traction with manufacturer • High transaction costs of in line inspections • Lack of proper documentation from manufacturer
not available • Ignorance around quality challenges with module
How is module quality managed for large MW sized projects
Why is module quality assurance not available for small kW sized projects
Module Manufacturing
Module Transport & Storage
Module Installation
Material for Module Manufacture
Check BoM Acceptance Tests
• Visual Inspection • Flash Test • EL Test
Certification by 3rd Party Agency – certificate with test results *e.g. UL, TuV etc.
Distribution Utility Discom to check
Certificates provided by 3rd Party Agency
Review of acceptance test results - Visual Inspection, Flash Test, EL Test & LID Thermal Imaging Test by Vendor Rating Agency
Vendor Rating Agency
3rd Party Module Quality Certification Agency
Potential Module
Aggregator/ Distributor
The Distributed Solar PV Project Development Chain – Implementation Framework for
Module Quality Assurance (2)
Distributed Solar PV Project Development Chain –
Pathways to achieving improved quality in Modules
Design of Module Aggregation Methodology
Identification of Agency for Aggregation(s)
Module Testing & Certification Protocol
Creation of Module Procurement Aggregator(s)
1) Quality Checks by inspection agencies 2) Aggregation of demand from small developers/ EPC
Distributed Solar PV Project Development Chain – The Opportunities & Challenges
in Module Quality Certification
• Limited to components & that too mostly modules
• No input on system design & installation
• No mandate & no institution working on this aspect at present
Challenges
• Brings economies of scale
• Lower transaction costs & low cost of quality assurance
• Specialised agency for purchasing key components
• Improved quality assurance
Opportunities
NREL | 38
Select
Recommendations 2 –
Safety Checks
through Distribution
Utility
The Distributed Solar PV Project Development Chain – Implementation Framework for
Safety through Discom (1)
What are the challenges to ensuring safety in Distributed PV Installations: 1. Safety checks by in large ignored – mostly a mandate of Discom or CEI 2. Some safety features not mandated 3. Consumer ignorant about safety – accepts compromises for cost cutting
• BESCOM – Interconnection Process mandates use & audit of safety features
• Kerala CEI – Published standardized Single Line Diagrams including safety devices specifications
• Some state regulations also mandate safety features in solar rooftop systems
• IECRE – NREL’s standards for rooftop systems operations document includes safety features.
• Only Discom responsible for checks & inspection of every rooftop project – i.e. the Discom
• Solar rooftop not a priority for Discom Enginers • Most Discom Engineers lack understanding of
solar rooftop & consequent safety issues – lack of training
• Site inspection & report generation time consuming for Discom Engineers.
• Lack of tools to fulfil the role
Few Examples of Safety in Distributed PV
Why is safety not a priority for small kW sized projects
The Distributed Solar PV Project Development Chain – Implementation Framework for
Safety through the Discom (2)
Responsibility of Discom
Key Challenge – Proper verification of Quality of Work
Verification of Inspection Reports of CEIG/ Discom by
Vendor Rating Agency
Easy to Fill Checklist based Tool
on Smart Phone
Training & Capacity Building Standard Operating Procedures
for Safety Documented in Regulation
Junction Boxes E&L Protection Site Access STAAD Pro
Certification by Structural Engg.
Distributed Solar PV Project Development Chain – The Opportunities & Challenges
in Safety Assurance through Discom
• System Quality – of limited interest for Utility
• Limited capacity of utility personnel
• High bandwidth requirements from utility personnel
Challenges
• Comprehensive coverage – as all sites visited
• Deep understanding & concern about safety issues
• Lowest transaction cost • Concurrent monitoring
Opportunities
NREL | 42
Select
Recommendations 3 –
Vendor Rating
The Distributed Solar PV Project Development Chain – Implementation Framework for the
Vendor Rating Framework (1)
• To provide a mechanism to evaluate
quality of onsite work (design,
components, installation) & performance
of systems
• To provide a comprehensive evaluation of
vendors – infrastructure, manpower,
systems & tools
• To generate performance data of various
components & systems
• A single point of reference for
stakeholders (consumers, FI’s &
developers) to identify quality vendors
What is a Vendor Rating Framework?
• Rating will be voluntary & based on benefits
in business that come to vendors with
ratings
• Framework will look at Vendor systems and
processes as well as sample installations to
arrive at a rating score
• Rating will be time bound and rolling in
nature
• Sampling of systems will allow vendors to
continuously improve ratings
• Ratings will be available to vendors to
advance business interests
How will the vendor rating
framework work?
The Distributed Solar PV Project Development Chain – Implementation Framework for the Vendor
Rating Framework (2)
A specialized agency like CII, TERI, GERMI
etc. with:
• prior experience in undertaking ratings
• independence
• a pan India presence
• excellent working relationship with
industry
• domain knowledge & industry
experience
• ability to train manpower & procure
equipment
Agency will develop a detailed framework for
rating vendors and a business model to make
this work financially viable
Who will be responsible for Vendor Rating?
Vendors:
Tool for business promotion; and
Benchmarking & improvement tool
Developers:
Tool for identifying quality vendors (EPC/installers);
Performance of systems on ground;
Lower transaction costs; and
Lower interest debt
Consumers:
Enhanced quality systems;
Cost competitiveness & Vendor comparison;
Consumer education & awareness; and
Lower interest debt
Bankers:
Quality of vendors & systems; and
Performance of systems on the ground
What are the benefits of a Vendor Rating
Framework for key Stakeholders
The Distributed Solar PV Project Development Chain – Quality Assurance
through Vendor Rating Agency (3)
Quality Measurement • Plant Performance • Module Tests – Thermal
Imaging • Array Layout Quality • String Inverter Design
Quality • Fastener & Structure
design Quality • Soil Resistance Test
Vendor Rating Agency
Vendor Rating Framework
Compliance Functions • Module Test Reports • STAAD Pro Report &
Galvanisation Compliance • Fire Safety Regulations • Protection Device
Compliance • Provision of Earthing &
Lighting Protection
Distributed Solar PV Project Development Chain – Pathways to achieving improved Vendor
Rating
Identification of an agency for managing Vendor Rating Framework
Key parameters for Rating Vendors
Marketing & Usability of Rating
Framework
Training Rating Agency/ Rating Professionals
Rating Methodology
Rating framework for EPC/ Vendors
IT Application for Consumers for Vendor/ System Selection
Database of Rated Vendors/ Systems for
Banks & FI’s
Performance Database Creation
Awareness on Quality amongst Consumers/
FI’s
Distributed Solar PV Project Development Chain – The Opportunities & Challenges
in implementing a Vendor Rating Framework
• Can be undertaken on sample basis
• Will be costly – need a business model
• Ex-post and not Ex-ante • Need to simplify rating system for
consumers
Challenges
• Ability to rate components, design & workmanship
• Comprehensive Assessment • Trained manpower • Appropriate Instruments • Detailed Analysis of each site
Opportunities
Next Steps
• Develop Implementation Plan for Recommendations
• Identify Vendor Rating Agency
• Design Rating Framework
Design Stage
• Create framework for module quality assurance by 3rd Party
• Modify Utility Procedures to include safety & quality better
• Develop outline & functionality for an app for utility engineers
Implementation Stage • Launch Vendor Rating Framework with Agency
• Backstop agency in rolling out the Vendor Rating Framework
Support Stage
Thank You for Your Time &
Attention
Cre
dit
: Ph
oto
sto
ck
The Distributed Solar PV Project Development Chain – Key Quality & Safety issues, their
impact on Project Returns & Potential Solutions
S. No. Stage of Project
Development
Key Issue Potential Solutions
1
Design
Array Layout Array layout to conforms to shadow analysis drawing – check drawing with actual layout
2 String Inverter Matching
PV Syst/ PV Sol reports should be used to verify proper matching – on site matching – post installation
check
3 Site Access
Pathway next to array for R&M; Access to modules – without specialised equipment and Provision of
lifeline for safety
4
Components
Structures 1. STAAD Pro Certification
2. Material treatment
5
Modules
• Bill of Materials
• Acceptance Testing
• Flash Test (At factory)
• EL Test (At factory)
• LID (At factory)
• Visual Inspection (At factory)
• Thermal Imaging (At site)
6 Junction Boxes Integrate with Inverter or test all protection devices
7 Installation E&L Protection
1. Lightening arrestors effective radius covering array
2. No. of Earthing's – Min. of 3 for each system
3. Soil Resistivity in each Earth pit < 5 Ohms
8 Handling of Modules 1. Thermal Imaging Test – and compare results with flash test
The Distributed Solar PV Project Development Chain – Approach to Implementation
Framework Development