solar project report 2

7/31/2019 Solar Project Report 2

http://slidepdf.com/reader/full/solar-project-report-2 1/19

INDIA'S FIRST MW LEVEL SOLAR PV POWER PLANT –

MY DREAM PROJECT

S.P.Gon Chaudhuri

Managing Director, WBGEDCL

Energy is a key input to economic growth and for improved quality of life.

Continued access to unrestricted supplies of energy is of major importance to

all economics India's Energy Policy till the end of the 1980s was mainly based

on availability of indigenous resources. Coal was by far the largest source of energy. Things have changed since then Coal and lignites share in the

commercial energy has come down further. The reason being non-availability

of good quality coal and also environmental issues. In order to fill up the gap

between demand and supply Renewable Energy has to play a major role in

India. Out of many forms of Renewable Energy Sources Solar Energy appears

to be most attractive. The world over installation of PV cells and modules has

been growing at an average rate of 35 percent since 1998.

There are two routes for converting Solar Energy into electricity. One route is

by collecting Solar Energy as heat through concentrating Solar Collectors and

converting this heat into electricity using a typical thermal power generating

unit. This is known as solar thermal power generation. The other route is by

using Solar cells to convert the radiation from the Sun directly to electricity.

This is called Solar Photovoltaic power generation. Sunlight can be convertedto electricity due to the photovoltaic effect discovered in 1839 by Edmund

Becquerel a French scientist. Sunlight is composed of photons or packets of

energy. This photon contains various amount of energy corresponding to the

different wave lengths of light. When photos strike solar cell electricity is



generated in the external circuit. Historically, it has been about 50 years since

the first operational silicon solar cell was demonstrated. However, the last 20

years have seen large improvements in the technology, with the best confirmed

cell efficiency being over 24.7%( laboratory level). The commercial crystalline

cells having efficiency around 20% is now available in the market.

Manufacturers claim that thin film module can be produced as low as 1

US$/Wp by the year 2011. However, wafer based crystalline silicon solar cells

have dominated the solar PV industry since the advent of the Solar era.

Crystalline Silicon is widely available, reliable and well understood. In the

previous decades the Solar Industry grew by almost 50% annually. Crystalline

Silicon has had about 90% of the total volume in the market.

Photovoltaic Power System Types.

Terrestrial photovoltaic systems can be categorized into three application

types: Stand alone, hybrid and grid connected.



The stand alone system generally involves batteries and is used in remote areas

which have no access to a public utility grid. A hybrid system includes a PV

array one or more auxiliary power sources ---- wind or diesel generator and one

or more batteries. Although it requires a more complex controller than the

stand alone or the grid connected systems, its overall reliability is superior to

the other two systems.

In grid connected system, the utility network acts as an infinite energy sink andaccepts all available power from the PV system. The simplest grid connected

system has a PV array and an inverter. For high voltage grid connected system

(greater than 230 or 415 volts), transformers and appropriate power switching

and protection devices are essential. However, the grid interface criteria vary



with the utility companies and not yet been standardized nationally. Most of

the inverters now being seen for grid connected applications incorporate peak

power tracking capability. That is the inverter controls the PV array out put to

maintain operation at its maximum power point which changes rapidly with

variation in Solar intensity and module temperature.

Solar PV in India.

The demand for power in India and consequently, the demand supply gap, is

growing over the years. Solar PV has the potential to be deployed in some key

segments like grid connected power generation, decentralized distributed

generation, roof based solar PV. The total Solar energy potential in India is

huge and this may contribute significantly in bridging the gap between supply

and demand Today, India experiences an average energy (electricity) shortage

of 9.6% and a peak shortage of about 14%. Peak shortage is highest in the

western and northern region of India where the availability of Solar radiation is

also comparatively high. To meet the growing demand and shortage of energy,

the generation capacity needs to be doubled in 10 years from the current levelof 1,45,000 MW (approximately). The country needs to deliver a sustained

growth of 8-9% through 2031-32 and meet the energy needs of its citizens.

India will need about 800 GW of power by the year 2031-32 according to the

planning Commission. The country at best can generate 500,000 MW of Power

from coal and 100,000 MW of power from Hydro. The quality of Indian coal

is not good. Large hydro power stations are seriously threatened by climate

related issues. The contribution of nuclear power in the energy basket of the

country may not be more than 50,000 MW by the year 2031 due to various

techno-political issues. There will be a net shortfall of power to the extent of

1,50,000 MW even after considering other sources like natural gas etc. This

gap may be filled up by various forms of Renewable Energy Sources amongst



which Solar energy appears to be most prospective. World wide Solar

installation has crossed 16 GW. Unfortunately due to absence of lucrative

policies Indian contribution in this major event is insignificant.

India has done impressive work in the area of stand alone type Solar

photovoltaic. The Ministry of New and Renewable Energy launched a country

wide Solar photovoltaic programme almost two decades ago. Under this

programme, almost one million Solar PV based systems have been installed

including 5.85 lakhs of solar Lanterns, 3.64 lakhs Solar Home Lighting

Systems, 69,500 street lighting system, 7,068 Solar water pumps and few small

Solar PV Power Plants. Though number wise installed Solar PV system inIndia is impressive however, MW wise the installed capacity of Solar PV is

very low in India. The installed capacity of Solar PV can only be increased

significantly through installation of MW level grid connected Solar projects.

The initiative towards setting up of MW level grid connected Solar project was

first officially discussed in the country in a workshop held at Kolkata in the

year 2006 where some state Electricity regulators were requested to declarefeed in tariff for grid connected Solar PV power plant. Secretary MNRE,

Government of India also argued in favour of the idea. The high cost of Solar

PV equipment results in a higher cost of generation, which restricted the

growth of power generation through Solar PV. However, finally MNRE,

Government of India decided to support large sized grid interactive Solar

Power generation projects. The ministry announced a generation Based

Incentive (GBI).

Scheme to support a total capacity of 50 MWp from 2007 to 2012. The state of

Punjab and the state of West Bengal first declared the feed in tariff in the



country. The State of West Bengal went one step ahead by declaring feed in

tariff for Roof Top Solar PV system also.

The salient features of GBI schemes are:

a) Solar PV Power generation plants of a minimum installed capacity

of 1 MWp per plant; either a single unit or modular units at a single

location will be eligible for generation based incentive

b) GBI is available only for a maximum cumulative capacity of

10MWp of grid interactive Solar PV Power generation projects in a

state.

c) The incentive scheme is applicable only to those projects that are

connected to the grid.

d) The GBI scheme guarantees an overall tariff of Rs.15 per KWh

which is the sum of GBI plus the preferential tariff offered by the

state utility.

e) Any project that is commissioned after 31 st December, 2009 would

be eligible for a maximum incentive with a 5% reduction and ceiling

of Rs.11-40 per KWh.

2 MW Asansol Solar PV grid connected Power Plant.

The power plant was conceived under the above mentioned scheme inFebruary, 2008 in a meeting where Secretary, MNRE, Managing Director of

DPSC Ltd. and the author of this article was present. Interestingly DPSC

offered the land free of cost in an old coal based Power Plant site. The 6 MW

old power plant was declared as abundant in the year 1997.



It was difficult for an Indian to make the Project Report since there was no past

experience. However, with great difficulties that project proposal was prepared

and financial closure was done with the Power Finance Corporation. It was

really a bold step for PFC to come forward to provide fund for the project at an

interest rate of 9%.

A number of clearances were obtained thereafter and finally the contract was

awarded to a Hyderabad based Company who started executing the Project in

collaboration with a German Company and under the overall supervision of

West Bengal Green Energy Development Corporation. The Plant is now ready

for export of power to the grid.

The Asansol Project is unique in many ways.

• This is the first grid tied MW level Solar PV Project in the country.

• The Project for the first time used indigenous 250 KW level Power conditioning

units in the country.

• Multifunctional MMS (Module Mounting structure) fixing machine was used for

the first time in the country.

• This is first Solar Mega Project in the world which replaced a small coal based

thermal power plant.

Salient Features of the Power Plant

Site Information:

The Plant is installed at Jamuria (Sheebpur thermal power plant site) Asansol,

West Bengal, India. Its co-ordinates are:

Latitude : 23.7o N



Longitude : 87.1o E

Altitude : 364 m above MSL

The site is about 210 Km from Kolkata, the major metro city in the Eastern

India. The site is approachable by road and rail.

Site Constraints:

There are some coal mines in the nearby area which may cause deposition of

dust on the modules. In such case the modules will require frequent cleaning.

Plant Architecture and Layout:

Rail Line

Solar Radiation and Climatic Conditions:



Insolation, global horizontal:

• Annual : 1900 kWh/m2

• Daily average : 5.4 kWh/m2

• Best performance month : October/November and February/March

• Ambient Temperature : 44o C maximum

: 8oC minimum

• Wind speed : 120 kmph (maximum)

System Description:

The PV arrays have been installed in the ash pond area of an old thermal power

plant named as Sheebpur Thermal Power Plant. The arrays have been installed

in a plot of land measuring 5 acres. There are 14 rows of PV panels. The

panels face truly south. In the lay out and design of the module mountingstructure adequate care has been taken in regard to wind speed and soil

condition. The MMS are made of I-channel and wooden beam.

All the sides of the PV array are free from any structure and there is hardly any

chance for construction activities in future. So there is no threat of shadow on

the module yard in future. 33 kV grid substation is only 200m away from the

SPV power plant.

Major components and their Features:

Solar Array



Rated Peak Power : 1250 kW (1st Phase)

Array Tilt Angle : 20o

Bus voltage : 670 -750 V

Number of strings : 191

Total Number of Modules : 4600

Number of Modules per string : 24

Module Manufacturer : Titan Energy Systems Limited,

Hyderabad

Module Rating : 240/225 W

Number of Cells per Module : 60

Module weight (Av) : 18.5 kg

Module dimension : 1667mm x 994mm

Module area : 1656998mm2

Solar cell Type : Crystalline

Cables : All DC cables are copper cable

with XLPE Insulation and cables are

directly laid into the ground. AC

cables are Aluminium/copper



conductor XLPE. HV cables are

XLPE type

Inverter (PCU):

Rated Power : 250 kW each

Number of Inverters : 5

Manufacturer : Optimal Power Synergy

Systems Ltd., Salt Lake, Kolkata

Input Voltage Range : 450 – 800 VDC

Output Voltage Range : 400 VAC (compatible with grid

voltage)

Frequency : 50 Hz ± 2.5%

Efficiency at Full load : 93%

Data acquisition system : SCADA in built in Inverter (PCU)

LT panel : 2000 Amp with 5 incoming and

1 out going with ACB on the

outgoing feeder.

11 kV Circuit Breaker : Indoor type

Transformer : 0.4/11 kV, 1.5 MVA, outdoor

type oil cooled



Component Description:

Modules - The modules are of 240W/225W size manufactured by Titan Energy

Systems Ltd. The cell assembly is laminated between glass/PVB and

tedlar/aluminium/tedlar. Electrical connections are made with quick connect

plug. By pass diodes are mounted in the termination box. Each module has 60

crystalline silicon cells of size 156 mm x 156 mm.

MMS (Module Mounting structure) - The module mounting structures are

designed to allow a simple assembly and installation of module and cabling.

The Module Mounting Structures comprising of galvanized M.S. I - beam

sections properly embedded and grouted in the ground along with treated

wooden beam properly fitted so as to withstand wind speed of 200 kmph.

Solar Array

The array comprises of 191 strings in total. Each string has 24 PV modules in

series. All the cables are underground type.

Array Cablings

All array cables are made of copper and XLPE cables of 1000VDC grade.



Data collection - The data acquisition system scans the solar, meteorological

and PV system data every minute and records the average values of these date

once in every hour. The system has been designed for autonomous operation.

Array field Control

Room

Power Evacuation - The Solar Power Plant is connected through a short 11

KV line ( 200 mtrs) up to the 33 KV grid substation of the utility. The LT

Power from the Solar Power Plant is stepped up to 11 KV by a 0.4/11 KV,

1500 KVA transformer. The HT line and the transformer is protected through a

suitable circuit breaker. 11kv XLPE type cables have been used to connect the

circuit Breaker and the transformer

Lightning Protection - Lightning protection consist of proper earth grounding

of all array structures and other electrical equipments. L.A s have been

provided in the substation.

Earth mat has been provided. Special earthing has been arranged for inverter

and transformer.

Instrumentation – All electrical equipments including Inverters, LT

panel, Transformer and HT gear have been provided with ammeters,

voltmeters, power-factor meters, kWh meter and meter as and where required.



Calibrated Energy meters have been installed to measure the quantum of export

of energy.

Conclusion – Solar PV is a technology that offers a solution for a number of problems associated with fossil fuels. It is clean decentralized, indigenous and

does not need continuous import of a resource. On top of that, India has among

the highest Solar irradiance in the world which makes Solar PV all the more

attractive for India. The state of Orissa and Andhra Pradesh also houses some

of the best quality reserves of silica. India has a large number of cells and

modules manufacturers. In spite of all above advantages Indian Photo Voltaic

programme is still in the infancy stage. One of the reasons could be absence of simple, action oriented and aggressive PV policy of the country both in the

state and central level. More quickly we do it with the professionals more we

protect our future energy security.

---------------------------------------------------- --------------------------------------------

PROCON ENGINEERSProconengineers.org

Solar PV Power Plants

Basic Engineering for Feasibility Study and Detailed Project Report:

Selection of Technology (Type of Solar Photovoltaic like Crystalline or Thin Film)

Selection of basic type and size of modules

Selection of basic array size and the inverter size.

Preliminary Plot Plant and Equipment Layout drawings.

Selection of size and type of various auxiliary systems equipments.

Conceptualization of power evacuation system and power distribution system depending upon type

and operating philosophy of Power Plant.

Conceptualization of Instrumentation and Controls requirements

Conceptualization of Civil and Structural works requirement

Estimation of project cost and unit generation cost

Detailed Engineering Services

Solar PV Power Plants



Mechanical

Plot Plan and Equipment Layouts for various buildings and area

Selection of technology and Array Design

Electrical

Design of power evacuation system.

Design of inverter system.

Design of cabling details and cable layouts.

Estimation of auxiliary power (Normal and Emergency).

Design of High Tension and Low Tension power distribution system.

Design / Sizing and specification of Electrical equipments like Transformers, Switchgear (H. T. & L.

T.), Cables, Lighting fittings etc.

Electrical system study including Relay Co-ordination.

Design and specification of Variable Speed Drives for special applications.

Design and specifications of various service systems like Plant Communication, Fire Alarm and

Detection.

Instrumentation

Design and specifications of Instrumentation and Control Systems including PLC, SCADA, DCS.

Architectural, Civil & Structural

Architectural, Civil and Structural design including estimation of quantities for tender document, tender

document for civil and structural works, plot development, drawings for statutory approvals and

construction drawings for all buildings / areas,

Procurement

Procurement assistance to client i.e. Floating the enquiries to selected Bidders, Receiving Bids, Bid

analysis (Technical and Commercial), Purchase recommendation, Preparation of Contract

documents, Review of Vendors’ Drawings etc.

General

Project schedules and Cost estimates.

Hazard and Operatability (HAZOP) Study.

Technical assistance to meet statutory requirements including drawings and documents.

Inspection and Expediting Services

Review of Quality Assurance Plans (QAPs).

Visiting Vendors’ works for inspection and expediting.

Inspection and expediting reports.



Construction and Commissioning Supervision ServicesComplete site supervision and management by deputing competent Project Manger / ConstructionManager and supporting staff at site. The responsibilities shall include:

Quality of construction / erection work.

Planning and controlling the Construction / Erection work to meet the project schedule.

Reporting to design office the site progress with short falls, if any, and corrective measures.

Solar Thermal Power Plants

Basic Engineering for Feasibility Study and Detailed Project Report:

Selection of Technology (Parabolic Trough, Fresnel, Solar Tower)

Selection of Reflectors and Receivers and the other components of Concentrating System.

Selection of power plant cycle and basic type of equipment.

Preliminary Plot Plant and Equipment Layout drawings.

Heat and Mass Balance for Solar Thermal.

Selection of type and size of power plant equipment i.e. Steam Generating Solar field and Steam

Turbine Generators, etc.

Selection of size and type of Material Handling systems (Water) as applicable based on type of power

plant cycle / equipment

Selection of size and type of various auxiliary systems / equipment e.g. compressed air system, Fire

protection system.

Conceptualization of power evacuation system and power distribution system depending upon type

and operating philosophy of Power Plant.

Conceptualization of Instrumentation and Controls requirements

Conceptualization of Civil and Structural works requirement

Estimation of project cost and unit generation cost

Mechanical

Plot Plan and Equipment Layouts for various buildings and area

Selection and specifications of Power Plant Equipment like Solar Field ( Solar Reflectors, Receivers

and associated systems) and auxiliaries, Steam turbine Generator and auxiliaries.

Design and specification of storage and handling system.

Design and specifications of Water systems, Compressed air system, HVAC system, Misc. material

handling system.

Design of P &I Diagrams for Feed water, Steam and Condensate system; Raw water and water

treatment systems; Cooling water system; Compressed air system.

Piping Design and Drawings including piping material specifications, layout drawings, isometrics,

stress analysis, bill of materials, pipe supports etc.



Design specifications for Fire Protection Equipments /Systems.

Electrical

Design of power evacuation system.

Estimation of auxiliary power (Normal and Emergency).

Design of High Tension and Low Tension power distribution system.

Design / Sizing and specification of Electrical equipments like Transformers, Switchgear (H. T. & L.

T.), Cables, Lighting fittings etc.

Electrical system study including Relay Co-ordination.

Design and specification of Variable Speed Drives for special applications.

Design and specifications of various service systems like Plant Communication, Fire Alarm and

Detection.

Instrumentation

Design and specifications of Instrumentation and Control Systems including PLC, SCADA, DCS.

Architectural, Civil & Structural

Architectural, Civil and Structural design including estimation of quantities for tender document, tender

document for civil and structural works, plot development, drawings for statutory approvals and

construction drawings for all buildings / areas,

Procurement

Procurement assistance to client i.e. Floating the enquiries to selected Bidders, Receiving Bids, Bid

analysis (Technical and Commercial), Purchase recommendation, Preparation of Contract

documents, Review of Vendors’ Drawings etc.

General

Project schedules and Cost estimates.

Hazard and Operatability (HAZOP) Study.

Technical assistance to meet statutory requirements including drawings and documents.

Inspection and Expediting Services

Review of Quality Assurance Plans (QAPs).

Visiting Vendors’ works for inspection and expediting.

Inspection and expediting reports.

Construction and Commissioning Supervision ServicesComplete site supervision and management by deputing competent Project Manger / ConstructionManager and supporting staff at site. The responsibilities shall include:

Quality of construction / erection work.

Planning and controlling the Construction / Erection work to meet the project schedule.



Reporting to design office the site progress with short falls, if any, and corrective measures.

Operation and Maintenance

Operation and Maintenance of the complete power plant with the agreed PLF

The scope of work can include spares contract also.

Complete plant operation and maintenance is managed by a dedicated team right from general

manager to assistants.

We have experience of operation and maintenance of plants of various sizes.

Welcome to Procon Engineers - Power Plant Consultants AndhraPradesh

Your trusted partners for Design, Detailed Engineering, Project management, Construction and

Operation & Maintenance of Power Plant.Our rich experience in power plant of various sizes (5 MW to 500 MW), fuels (coal, lignite, biomass,

renewable ) and in diverse geographies (India, Middle East, South East Asia) enables us to help our

clients achieve their goals of World Class Energy Solutions.

Power Plant Consultants: Engineering and Project Management Services for End to End Energy

Solutions

Feasibility reports

Detailed Project reports

Basic Engineering

Detailed Engineering

Procurement Assistance

Construction and commissioning supervision

Project Management

Operation and Maintenance

Energy Audit and Benchmarking Services

Headquarters:

PROCON ENGINEERS

(Division of Nimoto Consulting Engineers Pvt. Ltd.)

202-A, Dosti Pinnacle,

Plot No. E-7, Road No. 22,

Wagle Industrial Estate,Maharashtra. IndiaPhone: 91- 022- 64570461/ 64570462Email: [email protected]

http://www.proconengineers.org/power-plant-consultants-andhra-Pradesh.htm


mailto:[email protected]





solar project report 2

Documents