Upload
others
View
5
Download
0
Embed Size (px)
Citation preview
© 2011 Underwriters Laboratories Inc.
Session : Evolution in
Renewable Energy
Technologies
Sriparn Saurabh
Operation Manager, Energy.
UL India Pvt Ltd
1894 UL founded by William Henry Merrill
following 1893 Chicago World’s Fair
Funded and sponsored by the National
Board of Fire Underwriters
1897 Published list of approved electrical devices
1901 Name of Underwriters’ Laboratories, Inc.
1903 First UL standard published
1916 First international office opened in London
1958 Fire protection lab built
1980 UL/CCIC agreement for inspections
1988 Korea, Hong Kong & Taiwan offices open,
followed by many international offices
WORKING FOR
A SAFER WORLD
SINCE 1894
2
Some keyfacts about UL
3
TO HELP MAKE
THE WORLD SAFER
IN THE PLACES
WHERE PEOPLE LIVE
AND WORK
World’s leading electrical safety testing and
certification company
• 9,000 employees Leading safety brand
• 22 billion UL Marks on products
• 100,000 products tested annually Worldwide presence
• 67,750 customers in 104 countries • 97 labs and certification facilities across the
world
EXPERIENCED SAFETY
ENGINEERING
EXPERTS
Advancing Safety Science
• 100 Primary Designated Engineers
• 26 Fundamental Safety Researchers
Developing Safety Expertise
• 250k hours/yearly in Technical Training • Engineers & Inspectors Requalification
Sharing Safety Knowledge
• 1464 Published Standards
• Free* Access to Standards
Public Safety Services
• ‘Safety Smart®’ Youth Safety Education
• Anti-Counterfeiting Program
© 2011 Underwriters Laboratories Inc.
Reliability of PV modules
Three prong Path : Reliability on PV modules
To ensure appropriate design, installation, commissioning, and operation of PV systems:
1) qualifying the design for the intended application (climate zone and mounting configuration),
2) quality management systems for PV module manufacturing, and
3) system-level inspections
5
Applicable Standards
6 UL and the UL logo are trademarks of UL LLC © 2012
Standard Scope Description IEC 60904 series 1,2,3,4,5,7,8,9,10 ( measurement, ref devices, spectrum)
IEC 61730 Parts 1+2 / UL1703 ( safety)
IEC/UL 61215/ 61646 ci-S/TF IEC 62108 / UL 8703 CPV (performance)
EN 50380 / UL 4730 - Name plate rating and data-sheet
PV Module IEC 61853 Parts 1+2 - Module performance testing and energy rating
IEC 62716 - Ammonia corrosion, IEC 61701 - Salt mist test, IEC-draft 62804 - PID
IEC-draft 62788 - Encapsulants / Back&Frontsheets
EN 50521 / UL 6703 / IEC-draft 62852 - Connectors for photovoltaic systems
EN 50548 / UL 3730 / IEC-draft 62790 - Junction boxes
UL 4703 - Outline for PV wires
Inverter IEC 62109 Parts 1+2 /UL 1741 - Inverter
IEC 61727, 2004 Ed 2, Photovoltaic (PV) systems – Charact. of the utility interface
Local grid code requirements
IEC 60364-7-712, grid connection: Requirements installations or locations
IEEE 1547 Distributed Resources Interconnected with Electric Power Systems
EN 62305 Part 3 System grounding and lightning protection
PV Installation UL 2703 outline for mounting structures
EN 61439-1 requirements for combiner boxes
UL 4703 outline for PV wires
EN 50521 / UL 6703 / IEC-draft 62852 Connectors for photovoltaic systems
IEC 62124: PV stand alone systems
EN-61724 system surveillance during operation
System Survaillance IEC 62446 Grid connected photovoltaic systems – Minimum requirements for system commissioning tests and
inspection
IEC 61829 Onsite measurements of IV characteristics
IEC 62446 Grid connected photovoltaic systems – Minimum requirements for system documentation
PV Modules - Current State
7 UL and the UL logo are trademarks of UL LLC © 2012
Safety
Performance
Durability/Reliability
(Válquez & Rey-Stolle, 2008)
IEC 61730/
UL1703
IEC/UL
61215/61646
Specialized
Test Protocols
(PV QA Task Force)
Bankability – build confidence in the
module and its components to satisfy
the lifetime production goals of a
project.
What is Bankability?
8 UL and the UL logo are trademarks of UL LLC © 2012
UL formula for creating confidence and trust in PV modules, the
manufacturer and supply chain:
+ Safety testing - IEC 61730/ UL1703
+ Performance testing - IEC/UL 61215/61646
+ Statistical Sampling – representative cross section of
production
+ Extended Stress testing – configurations based on IEC/UL
61215/61646 (durability)
+ Conditional testing – specialization for operating
environment (durability)
+ Factory Inspection – assess product consistency within a
facility and across production sites (quality/reliability)
+ Company and Product Profile – assess sustainability of
the company, product and module warranty
---------------------------------------
= Bankable PV Modules
UL Bankability
9 UL and the UL logo are trademarks of UL LLC © 2012
1. Independent Performance Testing (extended)
2. Factory Inspection and QA
3. Company/Product Profile
Performance Testing
10 UL and the UL logo are trademarks of UL LLC © 2012
Test # Service Description
1 PID Sequence (ULdefinition) Evaluate module for stability under high potential.
2
Extended Temperature Cycle(TC) Evaluate modules for temperature changes and resistance to thermal
mechanical stressors beyond typical.
3
Extended Damp Heat(DH) Evaluate PV modules to moisture ingress under high temperature beyond
typical. (i.e high humidity applications).
4
Dry-Heat Testing Evaluate PV modules ability to withstand high temperature exposures ( i.e.
dessert applications).
5
Sequential Testing Evaluate PV modules ability to withstand multiple stressors beyond standard
requirements.
6 Salt Mist Test Evaluate PV modules for marine applications and corrosive environments.
7 Ammonia Test ( or other noxious gases) Evaluate PV modules for use in agriculture applications.
8 Mechanical Load (heavy load testing) Evaluate PV modules for use in heavy snow load applications.
9
Mechanical Fatigue Testing (wind) Evaluate PV module for use high-wind regions and serves as accelerated test for
mechanical fatigue ( 10,000 cycles).
10 Severe Hail Impact Testing Evaluate PV modules for use in severe hail environment.
11 Sand Impact Test Evaluate PV module for dirt and sand abrasion (ie. dessert applications)
12 Fire Test Evaluate PV module for resistance to spread of flame and burn through
13 Gel Content ( via Soxleth) Evaluation of PV module lamination stack to verify production process
14 Electro-luminescence Verification of cell integrity ( generally applied after stress tests and transport)
15
Infra-Red Imaging Verification of cell integrity. Typically applied after stress tests or shipping to
installation site.
16
Flash Test Sequence These services are aimed to check performance (power Pmpp) of the PV
modules.
17
Lot-by-Lot Comparison Aid in identify ng drifts and trends in manufacturing processes between shipped
modules
Potential Induced Degradation
(PID) Description: Evaluate module for stability under high potential. Also able to provide assessment of recovery periods.
Test Features:
•UL Specific Test methodology
•25°C, Aluminum foil on front plate,
Usyst = 1000V
•EL Imaging after each stage
•Stage 1: 168hrs: 1000W/m² +
200W/m²: Pass/Fail: 5% power loss;
40MOhm*m² min. insulation
resistance
•Stage 2: 336hrs: 1000W/m² +
200W/m²: Pass/Fail: 10% power
loss, 40MOhm*m² min. insulation
resistance
•Samples: 2 for each polarity + 1
spare for each BOM
Stage 0 Stage 1 Stage 2
<< Electroluminescent Imaging
Extended Temperature
Cycle(TC) Description: Evaluate modules for temperature changes and resistance to thermal mechanical stressors beyond typical.
Test Features:
•Per IEC/ UL 61215/61646 (heating
cooling ramp has to be 100°C/h)
•400 cycles (or Test-to-Fail) between
(-40°C) to + 85°C
•c-Si: Impp current
•thin-film: continuity check or Impp
•Samples: 2 + 1 spare for each BOM
Pass/Fail:
•TC-200: 5% power loss,
40MOhm*m² min. insulation
resistance,
•TC-400 (or beyond): customer
specific power loss, 40MOhm*m² min.
insulation resistance
Extended Damp Heat (DH) Description: Evaluate PV
modules to moisture ingress
under high temperature.
Test Features:
•Per IEC/UL 61215/61646
•2000 hours (or test-to-Fail), +85°C,
85% RH
•Optional: applying a current
•Samples: 2 + 1 spare for each BOM
Pass/Fail:
•DH-1000: 5% power loss,
40MOhm*m² min. insulation
resistance,
•DH-1500/2000 (or beyond):
customer specific power loss (default:
5% for 1500h, 8% for 2000h),
40MOhm*m² min. insulation
resistance
Dry-Heat Testing Description: Evaluate PV modules ability to withstand high temperature exposures ( i.e. desert applications)
Test Features:
•Configured as in IEC/UL
61215/61646
•2000 hours (or test-to-Fail), +100°C,
<15% relative humidity
•Optional: applying a current
Pass/Fail:
•Dry-Heat-1000: 5% power loss,
40MOhm*m² min. insulation
resistance, no discolorations
Sequential Testing Description: Evaluate PV modules ability to withstand multiple stressors for general application use.
Test Features:
•Per IEC/UL 61215/61646 (heating
cooling ramp has to be 100°C/h)
•Sequential test with damp-heat,
thermal cycling and humidity freeze
(cycle: DH:1000h +TC:200 + HF:10)
•Samples: 2 + 1 spare for each BOM
Pass/Fail:
•DH-1000h: 5% power loss,
40MOhm*m² min. insulation
resistance
•DH-1000+TC-200+x: power loss
defined by customer (default: DH-
1000+TC-200 5%, DH-1000+TC-
200+HF-10 8%), 40MOhm*m² min.
insulation resistance
•Repeat until target power loss
achieved or until major failure
Salt Mist Test Description: Evaluate PV modules for marine applications and corrosive environments.
Test Features:
•Per IEC 61701 ed 2, Severity 5, 28
days
•Optional: applying a voltage/current
•Samples: 2 + 1 spare for each BOM
Pass/Fail:
•5% power loss, 40MOhm*m² min.
insulation resistance
Ammonia Test Description: Evaluate PV
modules for use in agriculture
applications.
Test Features:
•IEC 62716 ed 1
•Samples: 2 + 1 spare for each BOM
Pass/Fail:
•5% power loss, 40MOhm*m² min.
insulation resistance
Mechanical Load (heavy snow) Description: Evaluate PV
modules for use in heavy
snow load applications.
Test Features:
•Mechanical load test per UL 61215
with applied loads of 5400, 7000 and
8000 Pa
•Per IEC/UL 61215/61646
•Test-definition: Front side loading:
5400+7000+8000Pa for 1hour each
with intermediate measurements after
each loading
Pass/Fail:
•5400Pa load: 5% power loss,
40MOhm*m² min. insulation
resistance, no cracking or bending
marks of/on frame or other parts
Mechanical Fatigue Testing Description: Evaluate PV module for use in high-wind regions and serves as accelerated test for mechanical fatigue ( 10,000 cycles)
Test Features:
•Dynamical load test with 10,000 cyc
and parameters per IEEE/ASTM 1262
•UL method: positive load 1440Pa (30
lb/ft2), negative load 0 Pa for
simulation of wind gusts
•Samples 2 Modules per mounting
situation + 1 reference/spare
Pass/Fail:
•5% power loss, 40MOhm*m² min.
insulation resistance, no breakage, no
constant deformation/cracking of
frame or other parts
Severe Hail Impact Testing Description: Evaluate PV modules for use in severe hail environment. (25mm are already performed by IEC certified modules).
Test Features:
•IEC/UL 61215 10.17, with ice balls of
35, 45, 55, 65 or 75 mm diameter
•Samples: 1 for each glass/Frame
type and each major design change
(e.g. glass/foil to glass/glass
construction) + 1 spare for each BOM
Pass/Fail
•5% power loss, 40MOhm*m² min.
insulation resistance, no breakages
Sand Impact Test Description: Evaluate PV module for dirt and sand abrasion (ie. dessert applications) which can affect irradiation absorption ability resulting in loss of power output.
Test Features:
•Procedure is based on the following
standards:
• NATO-AECTP 300, Methode 313
• IEC 60068-2-68
• IEC/UL 61215/61646/ 61730
•Samples: 2 + 1 spare for each BOM
Pass/Fail
•5% power loss, 40MOhm*m² min.
insulation resistance
Fire Test Description: Evaluate PV module for resistance to spread of flame and burn through.
Test Features:
•Per UL 1703 31.1,31.2 (UL 790
spread-of-flame, burning brand)
•Samples: up to 6 modules.
Pass/Fail
• At no time shall the brand burn a
hole through the roof covering or
through any part of the module or
panel.
•At no time shall the flame spread
beyond 6 ft for Class A, 8 ft for Class
B, or 13 ft for Class C rating.
Note: the UL1703 fire test
requirements are also proposed to
use in IEC61730-2.
Gel Content Description: Evaluation of PV module lamination stack integrity, a verification of the production process.
Test Features:
•Soxlieth Method ( 24 hrs)
•Differential Scanning Calorimetry
(DSC) mehtod ( ~1hr) - not available
•Extract EVA sample (coupon) out of
the laminate (1 - 5 grams) and
deposit in solvent and measure
weight percentage of non-soluables
•Samples: 2 + 1 spare for each BOM
Pass/Fail
•For encapsulation of PV the gel
content should be ≥ 80% and below
90%
Electro-luminescence (EL)
Snapshot Description: Verification of cell integrity ( generally applied after stress tests and module transportation)
Test Features:
•EL camera snapshot of charged
module ( DC power applied)
•Service delivered from all UL
laboratories ( not field capable)
•Image characterization reference to
UL catalog of failure attributes.
•Typically for customer information
only unless they ask for analysis and
interpretation.
Pass/Fail
•Criteria have to be agreed between
all involved parties in a project.
Infra-Red Imaging (IR) Description: Often used to verify module cell integrity, to verify proper field installation and discover damage that may have occurred during transit and construction.
Test Features:
•Performed in the field the PV
installation should be fully operational
and run at Pmpp
Pass/Fail
•Observational for customer
information.
Flash Test Sequence Description: These services are aimed to check performance (power Pmpp) of the PV modules and verify the name plate rating.
Test Features:
•Modules stabilized. Per MQT 19 of
IEC 61215-series.
Pass/Fail
•Averaged measured output power,
Isc and Uoc of all samples after MQT
19 must be within uncertainty
statement of Name plate of
manufacturer.
•Typical values are 0.6-1.0% for multi
c-Si modules and between 1-3% for
p-type Mono c-Si modules.
Lot-by-Lot Comparison Description: Aid in identifying
drifts and trends in
manufacturing processes by
examination of sampling of
modules ( staged at factory or
after shipment)
Test Features:
•UL determines sample size with
customer, based on ISO Acceptable
Quality Level (AQL)
•Determine with customer the
evaluation service suite (flash-test,
EL, PID, Gel content).
•Samples pulled and sent to UL lab
Pass/Fail
•Report defect rate per sample size
and lot size.
Overlay of cell defect per EL imaging.
OK 15 cell
defects
Not OK 79 cell
defects
Ongoing quality control: ISO 2859-1
ISO 2859-1 nicely defines:
• Sampling rates as a function of number of products
• Inspection levels (e.g. non-destructive / destructive)
• Acceptance limits for mass production
• Procedures to adjust sampling “Switching rules”
Switching rules
This scheme can be applied
to test from standards or to
customer specific tests
Inspection levels AQL
Example for sampling rates and tests
Inspection
level
Number of
modules for
testing
AQL (% non conforming items)
Test 0.1 0.15 0.25 0.40 0.65 1.0
10.1. Visual inspection G-1
a) 80
b) 200
c) 315
0
a) 0
b) 0
c) 1
a) 0
b) 1
c) 2
a) 0
b) 2
c) 3
a) 1
b) 3
c) 5
a) 2
b) 5
c) 7
10.2. Flash-Test (STC)
Flasher-List verification G-1
a) 80
b) 200
c) 315
0
a) 0
b) 0
c) 1
a) 0
b) 1
c) 2
a) 0
b) 2
c) 3
a) 1
b) 3
c) 5
a) 2
b) 5
c) 7
10.7. Low-light (200W/m²) S-4
a) 32
b) 80
c) 80
0 0 0 0
a) 0
b) 1
c) 1
a) 0
b) 2
c) 2
Power at different irradiance
and temperatures following
IEC 61853
S-2
a) 8
b) 13
c) 13
0 0 0 0 0 0
10.3. Insulation + 10.15. wet-L-
Test S-4
a) 32
b) 80
c) 80
0 0 0 0
a) 0
b) 1
c) 1
a) 0
b) 2
c) 2
EVA cross linkage Test
Lamination process/materials S-3
a) 20
b) 32
c) 32
0 0 0 0 0 0
PID-Test
(Destructive test) S-3
a) 20
b) 32
c) 32
0 0 0 0 0 0
Electro-Luminescence
Cell breakage/Defects G-1
a) 80
b) 200
c) 315
0
a) 0
b) 0
c) 1
a) 0
b) 1
c) 2
a) 0
b) 2
c) 3
a) 1
b) 3
c) 5
a) 2
b) 5
c) 7 29
Plant build with 240W modules: a) 1MW, b) 10MW and c) 50MW
What can you learn
from that data?
Customer Test Plan
30 UL and the UL logo are trademarks of UL LLC © 2012
Climate/Environment Specialized
Test
# Description
Mo
der
ate
( M
un
ich
)
Dam
p
(Ho
ng
Ko
ng)
Des
sert
( P
ho
enix
)
Live
sto
ck
Far
ms
Seas
ide
1 PID Sequence(ULdefinition) X X X
2 Extended Temperature Cycle(TC) R X
3 Extended Damp Heat(DH) R X
4 Dry-Heat Testing X
5 Sequential Testing R R R
6 Salt Mist Test X
7 Ammonia Test ( or other noxious gases) X
8 Mechanical Load (heavy snow load testing) X
9 Mechanical Fatigue Testing (wind) X X X
10 Severe Hail Impact Testing X
11 Sand Impact Test X
12 Fire Test
13 Gel Content R R R
14 Electro-luminescence X X X
15 Infra-Red Imaging
16 Flash Test Sequence X X X
17 Lot-by-lot comparison R R R
X = UL Required R = Recommended
Test Plan ( climate
specific) • UL1703/IEC61730
• UL/IEC 61215/62446
• Add Climate testing
• Add Specialized testing
• Add Recommended Test Plan ( general
need) • UL1703/IEC61730
• UL/IEC 61215/62446
• PID Sequence
• Extended TC
• Extended DH
• Dry-Heat
• Mechanical Load (heavy)
• Mechanical Fatigue
(wind)
• Severe Hail
• Add Specialized testing
• Add Recommended
Factory Inspection and QA
31 UL and the UL logo are trademarks of UL LLC © 2012
Realities of a production environment ...
• 24/7 production runs impact machine tolerances
• Variations in the supply chain ( purchasing decisions)
• Human error… from shift to shift, from night to day.
… drive need for Quality
Systems (QS) …
• Incoming goods inspection
• Process control and
verification
• Outgoing product
verification
• Training of personnel
… and periodic audits.
Factory Inspection and QA
32 UL and the UL logo are trademarks of UL LLC © 2012
UL has expertise in c-Si production processes …
Factory Inspection and QA
33 UL and the UL logo are trademarks of UL LLC © 2012
… and thin-film module fabrication.
Factory Inspection and QA
34 UL and the UL logo are trademarks of UL LLC © 2012
Item #
Name Description
1 General Information manufacturer registration, factory location, inspectors credentials, inspection type 2 Verification of
Components/Materials incoming inspection, certifications, non-conforming procedures/handling, records of goods.
3 Production Control, Inspection and Routine Tests
personnel qualifications, document control, process control, data recording maintenance and storage.
4 Functional Check of Test/Measurement Equipment
verification of equipment operation, assurance procedures, corrective action procedures, records maintenance.
5 Products Seen in Production tests include bonding, insulation resistance, dielectric strength, leakage current, wet leakage, power control, lamination cross link, pull test.
6 Calibration of Test/Measurement Equipment
verification of equipment and reference sources, traceability, records maintenance.
7 Handling and Storage components and materials storage and finished product storage compliance to standards.
8 Product Verification Tests/ Periodic Tests
in accordance to procedures, complaint to requirements, recorded and maintained.
9 Inspectors Findings summary of findings 10 Quality Management System certifications 11 Manufacturers Self
Assessment review and assessment
12 Customer Complaints review and assessment 13 Changes to Certified Products records review 14 Selection and Shipping of
Samples for Re-examination Identify sample for
15 Inspectors Evaluation findings and summary report
Company/Product Profile
35 UL and the UL logo are trademarks of UL LLC © 2012
The size, reputation, financial foundation, history
and product portfolio are key features that influence
the credibility of PV module manufacturers.
Product Portfolio
Company/Product Profile
36 UL and the UL logo are trademarks of UL LLC © 2012
Item #
Name Description
1 Company Profile - Overview of company structure, market and product offerings.
1.1 Company Structure The structure of the company including inter and intra company relationships.
1.2 Management Structure Included here is the management structure from C suite to vice president level.
1.3 Employees This section is a summary of the historic number of employees for the company or business unit under question.
1.4 Company Timeline This section is a summary of the company timeline and major events
1.5 Project portfolio This section is an aggregation of key projects the company under investigation has been a supplier for over the company history.
1.6 Research and Development Roadmap for efficiency improvements, Previous success in R&D, Trend of R&D expenditures over the years
1.7 Company Sustainability Company future plans
2 Product Portfolio - Included in this section is the list of products the client currently manufacturers.
2.1 Module Production Capacity (kW), Volume (# of modules) , Production sites, Number of employees, …
2.2 Product Specifics Product manual, Product photos, Product drawings, Certifications, BOMS,
2.3 Distribution This is an overview of the distribution network for the product under investigation. We are interested only in outgoing goods.
2.4 Warranty, Claims and Insurance As part of this section we will summarize the warranty for the specific product under investigation. Along with this we will also indicate the claim rates for the particular module and the current liabilities.
2.5 Module Performance This section is a summary of the module performance at from operating projects. The source of the data, environmental and commissioning dates will also be noted in this section.
2.6 Module Power Degradation This section will summarize the module degradation of the specific module under investigation. The sources of the data may vary and this will be noted in the report.
2.7 Module Efficiency This section includes a summary of the module efficiency over time. This is to be represented by a simple graph.
2.8 Module Cost per Watt This is a summary of the module cost per watt, which is too represented by a simple graph
37
Power Plant Services as Technical Partner