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8/8/2019 2. Execution and Commissioning
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PhotovoltaicSystemsTraining
Session2
Execution
and
Commissioning
http://www.leonardo-energy.org/training-pv-systems-design-
construction-operation-and-maintenance
JavierRelancio&LuisRecuero
GeneraliaGroup
September16th 2010
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PHOTOVOLTAICSYSTEM
Design,Execution,Operation&Maintenance
EXECUTIONANDCOMMISSIONING
JavierRelancio.GeneraliaGroup. 16/09/2010
www.generalia.es2
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INDEX
Civil works. Infrastructure preparation
Mechanical works
Electrical works
Environmental issues
Quality. Critical issues during execution
Safety & Labor risks
Commissioning tests. Key points
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INDEX
Civil works. Infrastructure preparation
Mechanical works
Electrical works
Environmental issues
Quality. Critical issues during execution
Safety & Labor risks
Commissioning tests. Key points
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5
Rooftop projects
We may find little civil works, but it will be reduced to the trench
opening for the connection of the inverters and the meters
Ground projects
Civil works are very important
A good definition for the civil works could mean an important
saving in the project.
Main civil works are:
Terrain leveling
Accesses and inside roads/paths Trench opening (AC & DC)
Civ i l W o r k s: I n f r as t r u ctu r e p r epar a t i on
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Ter r a in leve l ing
It might be avoided as much as possible in order to reduce the environmental impact
Only required works should be done:
Selecting a flat terrain may avoid its leveling
Selecting a structure type which can be fixed to the terrain by a ground anchor, instead
of a concrete base
Depending on the solution design, the choice between fixed or suntracking project can be
determinant
Source: QHOELET
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I n t er n a l r oa d s & p a t h s
It is recommended to use already existing paths
We must take into account that the roads or paths have to allow the circulation of
trucks. Truck turning radius must be considered:
Vehicle Type Nomenclature Height Width LengthLength
betweenaxis
Minimum radius forexternal front-
wheel
Minimum radiusfor internal back-
wheel
Light vehicle VL 1,30 2,10 5,80 3,40 7,30 4,20
2-Axis Omnibus B2 4,10 2,60 9,10 6,10 12,80 8,50
3-Axis Omnibus B3 4,10 2,60 12,10 7,60 12,80 7,40
2-Axis simple truck C2 4,10 2,60 9,10 6,10 12,80 8,50
3-Axis simple truck C3 / C4 4,10 2,60 12,20 7.6 12,80 7,40
Trailer (Semi) T2S1/ 2 / 3 4,10 * 2,60 15,204,00 /7,00
12,20 5,80
Trailer (Semi) T3S1 / 2 / 3 4,10 2,60 16,704,90 /
7,9013,70 5,90
2 Axis trailer + 1 Double C2 - R2 / 3 4,10 2,60 19,903,80 /6,10 /6,40
13,70 6,80
3 Axis trailer + 1 DoubleC3 - R2 / 3 /
44,10 2,60 19,90
3,80 /6,10
/6,4013,70 6,80
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Once the installation has been commissioned, internal paths & roads will not be used too
much, so a 25 cm depth path of a mixture 75% gravel, 25 % river sand, may be enough.
I n t er n a l r oa d s & p a t h s
Minimal turning radius forB3/C3 vehicles
Accesses and roads/paths detail
75% gravel, 25 % river sand
Natural terrain
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Trenches
In a PV project, all the cable must be buried underground
Each 40 meters or each direction change, a manhole will be placed to ease the cable
laying
The project design might try to use the same section for all the trenches
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Trenches
The trenches will have:
A river sand base
Space for the pipes
Backfill of sifted soil and soft sand
Cable caution tape
In the case it is a vehicle passingarea, it will have a concrete layer
at the top
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INDEX
Civil works. Infrastructure preparation
Mechanical works
Electrical works
Environmental issues
Quality. Critical issues during execution
Safety & Labor risks
Commissioning tests. Key points
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Mechan ical w o rk s
Structuretype Weight Anticorrosionprotection Mechanical
performance
Galvanizedsteel Resistantrooftops 8years(nonsaltyatmosphere) Good
Hotgalvanizedsteel Resistantrooftops Morethan25years Good
AnodizingAluminum Light
rooftops More
than
20
years Medium
Nostructure Lightrooftops
For fixed installations, the structure can be set parallel to the surface
where it is to be installed (flat), or with the optimum tilt for each
latitude (Tilted)
Flat Tilted
Nowind action Important windaction
Worse cooling Bestnatural cooling
Lowercost(Bothforstructure&
mounting)
Highercost(Bothforstructure&
mounting)
Photo: Krannich
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Mechan ical w o rk s
The structure anchor for a ground installation may
have the following possibilities:
Ground anchor
These screws have an average length
between 1 -1,6 meters
Easy to be dismounted
They can be adapted to the terrain orography
They cant be used in a rocky terrain
Concrete basement
Above or under the ground
It requires a flat surface
Easy to be dismounted (if it is above the
ground)
Source: Conectavol
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Roof anchor age
Metal roof anchors:
We have two options:
Direct to purlins anchorage
Specially designed anchors to be fixed directly to the roof
sheathing
I t i s r ecom m ended t o use t he d i r ect t o pu r l i n ancho r age . I f
t i l t ed s t ruc tu re i s be ing used , o th e r cho i ce cou ld be r i sky .
Tile roof anchorage:
A typical solution is using a U shaped piece which is
anchored directly to the roof, avoiding to drill the tile
It is necessary to move the tiles (danger of leaks)
With a special piece we can go through the tile
Danger to break the tile
Source: SoportesSolares
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Roof state:
The following aspects are to be evaluated:
Safety We have to verify if the roof is safe. If not, we may install lifeline, skylight
network
Roof type
Asbestos (Uralita) roofs are the most difficult ones, as it may be cracked by
stepping on it, producing leaks, or it could even be broken, being really risky for
the installers. In this case, it is recommended to change the whole roof to metal
roof.
PV Roo f s
Sealing
It is important to use the most indicated sealing to avoid
leaking. This sealers must have great elasticity and good
mechanical resistance. They may be complemented by
EPDM* bands
* a type of synthetic rubber (e thy l ene p r opy l ene d i ene M onom er )
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Loads on the roof
Material weight (average weight by square meter)
Wind effect
During the design, both panel height and exposed surface must be considered
Extra loads during the execution: such us tools, workers, materials
Accesses: The accesses will be distributed all along the roof surface, guaranteeing the
worker safety and allowing them to carry up small materials and tools
PV Roo f s
Element Weight
Structure 2KG
Crystallinepanels 15KG
Thinfilm glassglasspanel 22KG
Thinfilmlaminatedpanel 6KG
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INDEX
Civil works. Infrastructure preparation
Mechanical works
Electrical works
Environmental issues
Quality. Critical issues during execution
Safety & Labor risks
Commissioning tests. Key points
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Elect r i cal w o rk s
Cable for the panel strings
We usually use the cable included by the panel manufacturers.
Important to confirm with the manufacturer that this cable is included
This cable are composed of copper: 4mm; 0,6/1kV
This cables usually are ended in fast connectors: Multicontact,
Tyco, etc
Source: Eastech Solar
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Elect r i cal w o rk s
Roof installations
Cable canalization might be done under hot galvanized cable tray or tubular conduit
Cable tray canalization simplifies mounting works, and eases the maintenance tasks.
Indoor, plastic(or metallic) cable tray might be used, as well as halogen-free cable
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Elect r i cal w o rk s
Ground installations
Electrical works will be done in the trenches, so the cable must be designed for this use.
It is recommended to use anti-mice cable, inside a tubular conduit.
Cable trenches might be really long, so the
trench design, number of cables by pipeline,
extra space by pipeline, manholes, etc.. could
be decisive to optimize the electrical works
duration
The cable should be previously marked in order
to avoid connecting issues
It is important to avoid corners or any element
which may cause any damage in the cable
isolation.
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Elect r ica l cab inet s
Depending on its location, a different IP may be required
For outdoor installations, at least IP 65 will be required
For indoor installations, IP 21 could be enough (except for special conditions: water,
powder)I t i s r eal ly i m po r t an t t o pay a t t en t i on a t t he e l em en t connec t i ons , and t he
i den t i f i cat i on o f each cab le & com ponen t i n t h e p ro jec t docum enta t i on
The thermal study of the cabinet is also important, verifying the minimal required volume
for the heat dissipation, and raising additional solutions as the incorporation of a heatresistance in case of outdoor installations in very cold zones
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Ear t h ing syst em
The follow ing elements must be earth connected
PV panel frameworks
Structure Metal cable tray
Metal elements in electrical cabinets
PV inverters
For small facilities, the earthing system would be quite
simple: 2 3 pegs, depending on the soil resistivity
For bigger facilities, a cable grid is usually implemented,
using the trench already opened for the energy cables, placingan uncovered copper cable below the energy cables.
The section of this cable is to be calculated during the design
EARTHCABLE
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INDEX
Civil works. Infrastructure preparation
Mechanical works
Electrical works
Environmental issues
Quality. Critical issues during execution
Safety & Labor risks
Commissioning tests. Key points
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Nowadays we can find
A change in the social sensibility for the environmental impacts. The society begins to
have a greater conscience and a harder implication.
This will be the real engine for the new environmental initiatives to be managed in a
suitable way.
The ISO Certification 14001, allows us to take and to show the others, our
environmental commitment.
For all this, the solar power companies should demonstrate the coherence with their
ecological message, developing a good environmental policy
24
Our so lar f aci l i t y and t he env i r onm en t
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Definitions (ISO 14001):
Environmental aspect: Any element of the activities, products or services that is
causing some type of impact on the environment can be considered as an
environmental aspect.
Environmental impact: Any change in the environment, either adverse or beneficial,
resulting from the activities, products and services of an Organization.
Residue: Any substance or object from which his holder detaches or has the obligation
to become detached following the European rules & standards
Env i ronm en t a l aspect s & im pact s
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We must take into account the environmental management of our so lar facility
a. To know the in force legislation
b. To know the environmental aspects that concern our business
c. To evaluate the impact that has on the environment
d. To propose indicators that give us a tangible evidence about the measured aspects,
and their impacts, and to use them to develop new preventive and corrective
measures
e. To have an emergency plan derived from the knowledge of the different environmental
aspects
f. To do the suitable management of the generated residues
26
The environmental management becomes necessary in the execution, as well as the operation
of the solar plant, therefore, an individual analysis of every project will be required
Env i ronm en t a l aspect s & im pact s
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1. List of aspects and impacts
2. Emergency classification
Activity Aspect N/E Impact
PVinstallations(and
Suntrackers,incase
ofbeingused)
Electric
energy
consumption N
Atmosphericcontaminations
VisualImpacts
Fuelconsumption N Atmosphericpollution
Powdergeneration N Atmosphericpollution
Residuesgeneration N Spaceinthedumpsite
Fire EAtmosphericpollution
Impactonthefauna&flora.
N: Normal; E: Extraordinary
Exam p le: Env i r onm en ta l m anagem en t du r i ng t h e p r o j ect execu t i on
Aspect P S ASignificant
YES=Y;NO=N
Fire 2 4 8 Y
P: Probability; S: Seriousness; A: Assessment
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EVENT/EMERGENCY: FIRE
Preventive
measures Adaptation
to
the
electrical
and
construction
regulations.
Fire
extinguishers.
Actuationplan
Theworkmanageristhepersoninchargeoftheextinctionoffire.
Incaseofnoncontrollableemergency,theworkmanagerwilltakechargeof
warningtheexternalemergencyservices.
Theworkresponsibleisthepersoninchargeofgivingthealarmand
controllingtheevacuationofthewholestaff.Hemustcheckthatthe
evacuationhasbeencompleted
Practice Fire
Practicedescription
Theresponsetimewillbemeasuredforthefollowingaspects:
Thefirewarning.
Staffevacuation.
Thecheckingthattheevacuationhasbeencompleted.
Frequency Yearly
29
4. Emergency plan
Exam p le: Env i r onm en ta l m anagem en t du r i ng t h e p r o j ect execu t i on
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5. Residue management general process:
In every moment, we must:
To develop a study of the residues that are being produced, in the execution and theoperation of the solar power facility;
To quantify the quantity of each one, and to do a management of the residue
according to its type.
30
Urbanresidues Dangerousresidues
Paper Tonerwithmetalliccomponents
Plastic Batteries
Tins &Cans Fluorescents
Toner withoutmetalliccomponents Oils(Vehicles/Motors)
Exam p le: Env i r onm en ta l m anagem en t du r i ng t h e p r o j ect execu t i on
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INDEX
Civil works. Infrastructure preparation
Mechanical works
Electrical works
Environmental issues
Quality. Critical issues during execution
Safety & Labor risks
Commissioning tests. Key points
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Qual i t y : Cr i t i cal aspec ts
The critical aspects referred to quality in the phase of execution are:
Materials
Checking that we have received the goods that have been requested
Inspection of the goods at their arrival to check possible material faults/defects
This process will be developed for a certain number of samples previously defined by the
quality department
The checking of the electrical and mechanical parameters of the material, to avoid earlybreakdowns
Work execution
Correct planning of the work: in order to avoid delays, dead times of the workers,
managing the activities in critical way
Updated documentation for the works: It is important to check that the workers have the
latest edition of the information
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WorkManager
Qual i t y : Cr i t i cal aspec ts
Material Administration Material Reception
1.Checking that the items that have
arrived correspond to the items of
the delivery note
2.Visual checking
3.Checking of electrical and
mechanical characteristics
1.Checking that the items indicated in
the delivery notes corresponds with
the ordered ones
2. Checking any lacking item in the
order and claiming for it
3. Checking the payments
1.Checking that the ordered material fits
with the projects real requirements
2.Checking that the real project conditions
matched with the project design
3.Managing the material administration and
reception
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Work Manager
Worker
1. Work execution according to the
work order
2. To notify incidents in the
accomplishment of the works
3. Accomplishment of the checking
indicated in the work order
1. Fulfillment of the planning deadlines
2. Checking the documentation of the
work orders
3. Checking the quality in the
intermediate milestones of the project
4. Checking the management of the
residues during and at the end of the
project
5. Final checking of the work
Qual i t y : Cr i t i cal aspec ts
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Samplesselection
VISUAL ELECTRICAL THERMAL
Packages
PanelsOF
DETECTIONOF
Panel arrays Panels
Frame defects
Glass defects
Connection box defects
Cable & connector defects
The electrical
characteristics differ from
the technical specs, used
for the design and they
are out of the required
range
Cell defects
Hot spots
Cell bubbles
35
Pane l inspec t ion s
Although it might be true that the panels are the most expensive element in
the installation, a similar table should be done for the rest of the elementshttp://www.leonardo-energy.org/training-pv-systems-design-construction-operation-and-maintenance
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The Thermography is a simple method to detect defaults in the solar panels
The checking of the installation is developed in a rapid and visual form
It saves time, as it identifies directly the problematic panel without having to docomplex checks in the different strings
36
T he r mog r aphy
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INDEX
Civil works. Infrastructure preparation
Mechanical works
Electrical works
Environmental issues
Quality. Critical issues during execution
Safety & Labor risks
Commissioning tests. Key points
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1. Introduction
Within every company it is obligatory to have a labor risk evaluation plan.
Even in the case that we subcontract other companies, it is necessary to check that each
company has its labor risk evaluation plan adapted to our activity.
Knowledge
of
the
particularities
ofthecompanyactivities
Riskanalysisforeachactivity
Actions
depending
on
the
risks
Labor r i sk s eva lua t ion p lan
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2. Activitie character istics
PVontheroof PVontheground(Fix) PVontheground(Suntracking)
Smallfacilities:From23KWto100KW
(Orevenmore) Largerfacilities:>100KW Largerfacilities:>100KW
Workingatgreatheights Workingontheground Workingontheground
Differenttypesofroofs Earthmovements Earthmovements
Differenttiltsofroofs Trenchopenings Trenchopenings
Sharingtheworkwiththeindustry
whereourplantislocatedLargernumberofworkers Largernumberofworkers
Electricalcabling
and
inverter
commissioningPossibilityofusingcranes
Usageof
cranes
to
fix
the
panel
structure
totheSuntrackers
Electricalcablingandinverter
commissioning
Electricalcablingandinverter
commissioning
Labor r i sk s eva lua t ion p lan
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3. Activity risks
PVon
the
roof PV
on
the
ground
(Fix) PV
on
the
ground
(Suntracking)
Fallsfromtheroof Fallsintotrenches Fallsintotrenches
Accidentsduetomaterialfalling Toberunoverbyworkingvehicles Toberunoverbyworkingvehicles
Riskfrom
the
industry
where
the
plantislocatedElectrocutionrisk Electrocutionrisk
Electrocutionrisk Accidentsduetomaterialfalling Accidentsduetomaterialfalling
Accidentduetocollisionwiththesuntracker
40
Labor r i sk s eva lua t ion p lan
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4. Activitie summary
To analyze the photovoltaic activities, to know and to evaluate the risks of every job
inside every activity.
To train the staff on the risks depending on their job or workstation
To distribute the equipments of individual protection adapted to every workstation
To designate a person in charge of checking the correct execution of the prevention
plans
To develop an emergency and evacuation plan
41
Labor r i sk s eva lua t ion p lan
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INDEX
Civil works. Infrastructure preparation
Mechanical works
Electrical works
Environmental issues
Quality. Critical issues during execution
Safety & Labor risks
Commissioning tests. Key points
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Source: Geonica
Plan t p r oduc t ion check ing
Outdoor temperature
(Optional)
Irradiance
AC Power (at themeter output)
TEMP. PANEL FV
For the capture of the indicated
variables we will need to have:
A meteorological station
where the information of
Temperature and irradiance
will be registered
A meter (with integrated
communications) from which
we can read the output
power
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In the case of using suntrackers, we have to verify the equipment performance every
hour by testing the shadow projected by a rod perpendicular to the plane of the
generator
Minimal measure period: 5 consecutive days dawn - dusk
Condition: The minimal period of irradiance over 600W/m2 must be at least 12 hours
Periodicity of the measure of output power - irradiance-temperature: 10 mins
The obtained measures of output power-irradiance-temperature are compared to the
expected ones and the deviations between both are analyzed
If the legislation allows it in the future, the modernization or extension of the plant for
repowering might be recommended
Plan t p r oduc t ion check ing
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Test ing o f PV Genera t o r e lect r i ca l
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I
V
Test ing o f PV Genera t o r e lect r i ca l charac te r i s t i cs
We obtain the C-V curve from the generator and the
one from a standard module, and both are compared
under the conditions above-mentioned
These tests have to be done two hours before and after
the local midday and the global irradiance has to be a
over 700W/m2
Nowadays we can find specific equipments to obtain the
C-V curve of a PV generator and move it into standard
conditions
Objective: To determine the electrical characteristics underthe Standard metering conditions, defined by:
Irradiance: G = 1000 W/m2 Cell temperature: CT=25C.
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T t i f t h i t l t i l h t i t i
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Is the second most important element in a PV facility
The European efficiency of the inverter, has to be
verified with the measures commented in the previous
slides, attaching the power measure and the voltage
in the DC side
Furthermore, it must be verified the inverter capacity
to track the Maximum Power Point (MPP)
Test ing o f t he i nv e r t e r e lect r i cal cha ract e r i st i cs
Source: SMA
Objective: To determine the characteristics which define theenergetic performance of an inverter:
Efficiency Maximum Power Point Tracking
http://www.leonardo-energy.org/training-pv-systems-design-construction-operation-and-maintenance
En d o f Session 2
8/8/2019 2. Execution and Commissioning
49/49
49
http://www.leonardo-energy.org/training-pv-systems-design-
construction-operation-and-maintenance
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