2. execution and commissioning

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

http://www.leonardo-energy.org/training-pv-systems-design-construction-operation-and-maintenance


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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

3http://www.leonardo-energy.org/training-pv-systems-design-construction-operation-and-maintenance


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INDEX


Mechanical works

Electrical works







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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


Mechanical works

Electrical works







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12

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


Mechanical works

Electrical works







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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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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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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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21

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


Mechanical works

Electrical works







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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

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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

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4. Emergency plan




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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.

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Urbanresidues Dangerousresidues

Paper Tonerwithmetalliccomponents

Plastic Batteries

Tins &Cans Fluorescents

Toner withoutmetalliccomponents Oils(Vehicles/Motors)




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INDEX


Mechanical works

Electrical works







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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


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




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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


Mechanical works

Electrical works







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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



L b i k l t i l


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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



L b i k l t i l


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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




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INDEX


Mechanical works

Electrical works







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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


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.


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


En d o f Session 2


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http://www.leonardo-energy.org/training-pv-systems-design-

construction-operation-and-maintenance

Thank you for attending

2. execution and commissioning

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