Installation & Commissioning Report

128 KW Grid-Tied Solar Power Plant

Installed at: Masood Spinning Mill (MSM) Kabirwala

Installed By:

Premier Energy (Pvt) Ltd.

Solar Power plant Commissioned on: 24 August 2015

Signed By:

____________________ ____________________

Mahmood Ahmed Fazal Yasin

Manager Technical Operations Manager Electrical

Premier Energy (Pvt.) Ltd Masood Spinning Mill (MSM)

Background

Solar power in Pakistan is most suitable solution because of energy crisis, load shedding and power crisis.

Pakistan covers 796,095 square kilometers of land between latitudes 24 and 36north and longitudes 61

and 76 east. At present, it faces serious energy problems: 95 per cent of its electricity generation comes

from hydropower, which becomes less productive during the driest, hottest months of the year and cannot

keep pace with the sharp rise in energy demand. Also, about 70 per cent of the population lives in some

50,000 villages dispersed around the country. Many of these villages are far from the main transmission

lines of the national grid and, because of their relatively small populations; it is usually not economically

viable to connect these villages to the grid. Solar energy, on the other hand, has excellent potential in

areas of Pakistan that receive high levels of solar radiation throughout the year. Every day, for example,

the country receives an average of about 19 Mega Joules per square meter of solar energy. Hot, sunny

climate, long daytime hours and unstable grid power generation makes solar energy an ideal solution for

Pakistan. Kabirwala, due to its more summer hours, is ideal for solar power plant.

Before start of this project at Masood Spinning Mill (MSM) , we utilized meteorological data, using

temperatures, radiation scores and longitude and latitude readings to design the perfect solar energy

system customized according to the requirements of our clients. Air ducts roof were selected for

installation due to easy access to LT Room of Unit 2.

Project Details:

It is a 128KWp Grid tied project and consist of four grid tied ABB inverters TRIO-27.6-TL-OUTD.In

This System total 504 panels are used. 100 panels of Canadian solar and remaining 404 panels of

SunTech Solar are used. Inverter 1, 2, 3 is fed by DC input of 32.13 KWp that means 126 panels of 255W

for each inverter and remaining 4th inverter fed by DC input of 31.63KWp that means 100 panels of

250W and 26 panels of 255W. Each inverter consists of two MPPT controllers. Three strings of 21 panels

each are connected to each MPPT and in this way 6 strings are connected to each inverter. So we have a

total of 24 strings for 4 inverters. As the open circuit voltage of the panel is 37V, so the string voltage is

more than 700V in peak hours, suitable for MPPT operation in independent mode.

The DC cable used for each string to inverter is 6mm and the inverter to grid AC cable is 95mm and the

support structure consist of galvanized coated iron. For protection AC and DC disconnect switch, DC

over voltage surge arresters and AC over voltage surge arresters and string protection fuses are available

for each inverter. Also on AC side ABB 120 Ampere 4 pole breaker is used for every inverter. The

inverters are grounded using 4mm cable and Main DB panels is grounded by 35mm earth wire and

connected with main LT room earth point for earth protection. A set of 126 panels is made and is

grounded with 4mm cable.

Installed Equipment:

SR# Accessory Name Specs Quantity Total

01 Solar Panel (Poly) Suntech 255W 404 404 Panels

02 Solar Panel (Poly) Canadian 250W 100 100 Panels

03 Mounting Frames(Suntech) GI Adjustable 408 408 Frames

04 Mounting Frames (Canadian) GI Adjustable 100 100 Frames

05 Bolts for Panel fixing GI, 13mm,1 1112 1112 bolts 06 Nuts for Panel fixing GI, 13mm 1112 1112 Nuts

07 Washers for Panel fixing GI, 14mm 1112 1112 Washers

08 Bolts for Frames fixing GI, 13mm,3 1410 1410 bolts 09 Nuts for Frames fixing GI, 13mm 1410 1410 Nuts

10 Washers for Frames fixing GI, 14mm 1410 1410 Washers

11 Rawalbolts M8 (5/16) 1150 1150 Rawalbolts

12 Rawalbolts Washers GI 1150 1150 Washers

13 1 Core DC Cable 6mm,Pure cupper shielded

cable

405m 405m 1 Core DC Cable

14 2 Core DC Cable 6mm,Pure cupper shielded

cable

734m 734m 2 Core DC Cable

15 PVC Pipe 1 Popular Pipe 177 lengths 135 lengths 16 PVC Pipe 3 Popular Pipe 13.5 lengths 13.5 lengths 17 Earthing Wire frame to

frame 4mm single core 540 m 540 m

18 Earthing Cable 35mm From DB to Load

65 m 65 m

19 Flexible pipe 1 flexible pipe 8 bundle 8 bundle 20 Pipe joints, Bends, T joints 1 Popular Pak

Arab 100 pieces

of each item 100 pieces of

each item

21 Socket 1 Popular Pak Arab

150 pieces 150 pieces

21 Communication wire Networking cable

60m 60m

23 Communication Connector 485 to RS232 converter

1 1

24 AC wire 95mm 4 core shielded cable

Fast Cable

65 m 65 m

25 AC Breaker 80-100 A AC breaker ABB

4 4

26 Combined DB Panel Polarized coated iron

Set Set

27 Cable Duct 80 x 80 mm 48 Feet Cable Duct 48 Feet

28 Cable ties 8 PVC Cable Ties

13 Packets 13 Packets Cable ties

29 Regular tap PVC Regular Tap

8 Bundle 8 Bundle Regular tap

30 HT Tap HT Tap for Connections

1 1 HT Tap

Solar Panel Commissioning Data

Solar Panel Technical Data:

Model: SCT STP255-20/Wem:

Company/Brand: Suntech Polycrystalline

Voltage Optimum: 30.8 Volts

Short Circuit Current: 8.76A

Open Circuit Voltage: 37.6V

Operating Module Temperature -40 C to +85 C

Maximum System Voltage 1000 V DC (IEC)

Maximum Series Fuse Rating 20 A

Power Tolerance 0/+5 %

STC: irradiance 1000 W/m2

Module temperature 25 C, AM=1.5

NOCT STP255-20/Wem

Maximum Power at NOCT (Pmax) 188 W

Optimum Operating Voltage (Vmp) 28.1 V

Optimum Operating Current (Imp) 6.68 A

Open Circuit Voltage (Voc) 34.7 V

Short Circuit Current (Isc) 7.12 A

NOCT: Irradiance 800 W/m2.

Ambient temperature 20 C, AM=1.5, wind speed 1 m/s.

Temperature Characteristics:

Nominal Operating Cell Temperature (NOCT) 452C

Temperature Coefficient of Pmax -0.42 %/C

Temperature Coefficient of Voc -0.33 %/C

Temperature Coefficient of Isc 0.067 %/C

31 Copper Sleeves 35mm Copper sleeves

18 pieces 18 pieces Copper Sleeves

32 Copper Thimbles 35mm, For Ac output Wire Connections

20 Pieces 20 Pieces Copper Thimbles

33 Grid Tied Inverter 27.6 KW Grid Tied Inverter

4 Two 27.6 KW Grid Tied Inverter

Panel Installation Configuration:

Total Panels: 504

SunTech 255W: 404

Canadian 250W : 100

Total no of Strings: 24

Total no of panels per String: 21

Grid Tied Inverter:

Technical Data and Types:

Type code TRIO-27.6-TL-OUTD-S2X-400/JP

Input side:

Absolute maximum DC input voltage (Vmax,abs) 1000 V

Start-up DC input voltage (Vstart) 430 V (adj. 250...500 V)

Operating DC input voltage range (Vdcmin...Vdcmax) 0.7 x Vstart...950 V

Rated DC input voltage (Vdcr) 620 V

Rated DC input power (Pdcr) 28600 W

Number of independent MPPT 2

Maximum DC input power for each MPPT (PMPPTmax) 16000 W

DC input voltage range with parallel configuration of MPPT at Pacr 500...800 V

DC power limitation with parallel configuration of MPPT Linear derating from max to null

[800VVMPPT950V]

Maximum DC input current (Idcmax) / for each MPPT (IMPPTmax) 64.0 A / 32.0 A

Maximum input short circuit current for each MPPT 40.0 A

Number of DC inputs pairs for each MPPT 5

DC connection type Tool Free PV connector WM / MC4

Input protection:

Reverse polarity protection for inverter only, from current limited source, with max 2 string connected

Input over voltage protection for each MPPT - varistor 2

Input over voltage protection for each MPPT - plug in modular

surge arrester (-S2X version) 3 (Class II)

DC switch rating for each MPPT (version with DC switch) 40 A / 1000 V

Fuse rating (versions with fuses ) 15 A / 1000 V

Output side:

AC grid connection type Three Phase 3W+PE or Three phase 3W+N+PE

Rated AC power (Pacr @cos=1 ) 27600 W

Maximum AC output power (Pacmax @cos=1) 27600 W

Maximum apparent power (Smax) 30000 VA

Rated AC grid voltage (Vac,r) 400 V

AC voltage range 320...480 V

Maximum AC output current (Iac,max) 45.0 A

Contributory fault current 46.0 A

Rated output frequency (fr) 50 Hz / 60 Hz

Output frequency range (fmin...fmax) 47...53 Hz / 5763 Hz

Nominal power factor and adjustable range >0.995 Adj 0.8 with max 30kVA

Harmonic Distortion of Current each

Installation Installation of Solar Power plant with 128 KW Installed capacities was carried out in two stages.

Installation Phase 1

Before starting the work

Before starting the work our engineers compared the theoretical readings with the practical readings by

taking different short circuit test of SunTech panel (255W) at different tilt angles at Kabirwala.

They observed that the best output (8.3A) was achieved at tilt angle of 28 degree.

The panel orientation towards south was adjusted for maximum output.

A reference panel was set for the maximum output.

Panels installation were observed to be difficult because Air Ducts were 5 feet height from roof surface.,

Also it was too difficult to work during day time due to hot weather and working was then started at night

time and after that it was shifted at day time.

Panels installation

Work force for panel installation:

Two Engineers

Four Assistant Engineers

Two Technicians

Installation started:

Four assistant Engineers and two technicians started panels mounting in the supervision of two Engineers.

Panels were properly fixed with galvanized frames and then the structure was mounted on the roof using

proper bolts. All 404 panels were mounted by the same manner. 100 panel of Canadian solar was already

installed.

Making strings:

Strings were made by connecting a set of 21 panels to achieve the desired DC voltage level for the ABB

inverter. In this way a total number of 24 strings were made from all 504 panels.

Cables and cable piping:

A 6mm cable was used to connect each string with inverter, the connection was properly punched and

then insulation tape was used to ensure the safety. The cables were laid in the PVC Pipe and trenched into

the room.

Installation Phase 2

In this phase the four on-Grid inverters of ABB, AC cable 95mm, Cable for grounding, DB Panel and

other necessary accessories were transported to Kabirwala.

Grounding:

All panels were grounded in four working days using 4mm cable. A set of 126 panels were made and was

grounded with 4mm cable and connected with main DB Panel earth wire .The inverters were grounded

using 4mm cable. Similarly the DB panel was grounded using 35mm cable and connected with earth

point of LT room.

Inverters and DB installation:

The inverters were hanged on walls of the inverter room, two on each side of the room and beside of the

door DB Panel was hanged. The DB panel consist of 4 AC breakers, out of this four breakers were 80A to

100A (one for each inverter). The AC and DC cabling were done by proper PVC piping.

Checking polarity and string voltages:

The polarities of each string were then checked through multi meter and then male and female connecters

were connected to the positive and negative terminals of the strings accordingly. Meanwhile the string

voltages were checked at the same time it was observed 700 volts minimum in all 24 strings.

Solar Panel String Voltages

The polarities of each string were checked in field and then in inverter room through multi meter and then

male and female connecters were connected to the positive and negative terminals of the strings

accordingly. Following were the voltages of the strings with cable nomenclature:

String Name Voltage in field Voltage in

Inverter Room

1. Inverter 1- 1 A 726.70 V 719.6 V

2. Inverter 1- 1 B 720.44 V 709.8 V

3. Inverter 1- 1 C 723.42 V 714.8 V

4. Inverter 1- 2 A 728.91 V 721.7 V

5. Inverter 1- 2 B 740.03 V 729.1 V

6. Inverter 1- 2 C 743.28 V 732.8 V

7. Inverter 2- 1 A 718.15 V 710.2 V

8. Inverter 2- 1 B 719.17 V 711 V

9. Inverter 2- 1 C 727.57 V 719.3 V

10. Inverter 2- 2 A 718.56 V 710.4 V

11. Inverter 2- 2 B 734.99 V 727 V

12. Inverter 2- 2 C 718.32 V 710.3 V

13. Inverter 3- 1 A 738.62 V 729 V

14. Inverter 3- 1 B 741.79 V 733.4 V

15. Inverter 3- 1 C 723.16 V 715.3 V

16. Inverter 3- 2 A 721.81 V 712.2 V

17. Inverter 3- 2 B 732.13 V 723.1 V

18. Inverter 3- 2 C 719.32 V 710.3 V

19. Inverter 4- 1 A 695.38 V 690.2 V

20. Inverter 4- 1 B 694.22 V 689.3 V

21. Inverter 4- 1 C 695.21 V 690.2 V

22. Inverter 4- 2 A 696.44 V 691.2 V

23. Inverter 4- 2 B 695.47 V 690.4 V

24. Inverter 4- 2 C 720.09 V 714.6 V

Connecting the PV system to the Grid

The four inverters were connected to the Grid through a 95mm AC cable.

Configuration of the inverters

The independent mode was selected for the inverter, so that each the MPPT will operate

independently

The Italian grid standards were selected( equivalent to WAPDA Standards)

The language selected was English

The time was set according to the Pakistan standard time

Operation Start

All the four inverters were configured in the presence of ABB representative and were synced with

WAPDA. The operation was ok and all the inverters were working properly.

Commissioning Details:

Commissioning of this grid-tied solar power plant was carried out at 2:10 pm on 24 August 24, 2015.

With breaks of ten minutes duration all inverters were turned on one by one. Results were recorded which

at 2:00 pm were:

Inverter 1: 23.5 KWh

Inverter 2: 23.8 KWh

Inverter 3: 23.3 KWh

Inverter 4: 22.9 KWh

Communication and Monitoring:

Inverter communication is made possible with 485 networking protocol. For monitoring Aurora

Communicator software is used. An all inverts data displayed on desktop computer. An updating Email is

enabled for daily production monitoring. A Fault Email is also enabled so that in future if any fault may

occur then addressed that faults accordingly.

Checks & Protections:

PANEL:

Open Circuit Voltage Check: All 504 Panels were found with 32 Volts and above (in peak

hours).

Short Circuit Current Check: All 504 Panels produced 7 A and above (in peak hours)

All panel connections are checked and isolated and protected and proper grounding is made by earthing

wire.

INVRERTER:

Inverter output and all other parameters as per technical datasheet and check accordingly. All inverters

connection checked and all inverters a properly earthed with earthing wire.

DB Panel:

DB panel Isolation and connection checked. All cable connections are correct, isolated and protected. DB

panel is properly earth with LT Room earth wire.

Communication:

All communication setup is already checked. All inverters monitored on desktop computer and their

parameters.

Single Line Diagram of 128Kwp Solar Grid Tied PV system:

Special Thanks:

Premier Energy and its Project Team are thankful to Mill Management to support us in

energy stage of project which is no doubt looks very professional working.

Remarks:

Premier Energy recommends regular cleaning of PV Panels will be maintained.

Signed By:

____________________ ____________________

Mahmood Ahmed Fazal Yasin

Manager Technical Operations Manager Electrical

Premier Energy (Pvt.) Ltd Masood Spinning Mill (MSM)

(Pvt) Ltd