hydrocarbon 25% reduction in energy intensity of gdp...

“The era of a hydrocarbon

economy is coming to

its end”

Nazarbayev, 2012

15-25% reduction in greenhouse gas emissions below 1990 levels by 2030

708 12.2162.5122018 4.362

CoalHydro GasOil

Solar and wind to provide 3% of total power generation in 2020; 30% in 2030 and 50% in

2050

25% reduction in energy intensity of GDP below 2008 levels by 2020

Renewable generation - Announced• Samruk –Kazina Kyzylorda (50MW) – Solar• Samruk-Energo Kapchagay (2MW) – Solar• Shokpa Windwarm (400MW) – Wind• ENE – (50MW) – Wind

Installed generation capacity (MW) -2017

Kazakhstan has set up

ambitious goals to move to a

more sustainable

energy matrix

1

Construction

Module 1: Generation systems

Module 2: Project feasibility

Module 3:EPC

Module 4: Transmission &

Distribution models

Course structure

The following training is designed to get an overall understanding of Wind Generation from hands-on-work perspective, providing an overview of the main aspects of the Lifecyle of a wind

generation project

Wind generation

Storage

Protections

Cables

Allocation & Resources

Design & Engineering

Contracting Procurement Logistics

H&S

Grids -Mini GridsClustered DER

Mini utility, metering & Collection

Construction groundworks

Construction mechanical

Construction electromechanical

Construction handover

Utility scale

Forms of contracts

Regulation

Dimensioning & designing

Financial modelling

O&M

Inverters

2

Module 1.2Types of

generators Content

Module 1: Generation Systems & grid overview

Module 2: Project Feasibility

Module 3: EPC

Module 4: Transmission & Distribution Models

3

Solar PV. Solar Generation Side. Strings & Tables.

Inside a PV field the panels are fist connected in

SERIES: POSITIVE to NEGATIVE

This SUMS the VOLTAGES of all the panels connected this way.

WARNING: NEVER EXCEED THE WHOLE SYSTEMS VOLTAGE RATING PER STRING. USUALLY 1,000 V.(*). YOUR PANELS CAN CATCH FIRE !

In the past, for single user isolated systems based on rudimentary charge controllers and lead-acid batteries, with specially manufactured panels, after a short series connection a PARALLEL connection was done:

PARALLEL: POSITIVE to POSITIVE AND NEGATIVE TO NEGATIVE

This SUMS the AMPERES of all the panels or STRINGS connected this way.

WARNING: NEVER EXCEED THE CHARGER AMPERAGE RATING. YOUR CABLES WILL CATCH FIRE !

(*) There are systems designed for 1,500 V, but the whole system has to be designed for that level, panels, cables, protections and inverters. There are only 8 panel manufacturers who offer 1,500 V panels, but little stock available.

Solar PV. Solar Generation Side. Strings & Tables.

Strings are organized in “tables” and tables into “arrays”.

Cables between panels shall never jump between tables.

There are many possible configurations of tables, according to how many panels are in vertical order, normally it varies between 1 and 4.

The panels can be oriented either in vertical position or horizontal position, as by where their long side is oriented.

Here are some examples of tables:

Strings must follow the table

Strings can be routed on the table to reduce cable to reach the combiner of inverter.

Multiple strings can be routed on the table in different shapes to reduce cable to reach the combiner of inverter.

Wind. Generation Side. Plant layout.

T 1 T 2 T 3 T 4

> Diam x 10

T 5 T 5> Diam x 10

6

Module 1.3Storage

7

Generation Side. Storage Dimensioning.

TypeSingle

User/HouseSingle User Commercial

MiniGrid DEROn-Grid Solar

PV PlantDistribution

GridTransmission

Grid

OPZ Average Average NO NO NO NO

Li-Ion OK OK OKCompensate

VariabilitySmall scale(< 50 MWh)

NO

Flow NOGrid Cost

(> 1 MWh)24 h Supply (> 1 MWh)

24h Supply (> 5 MWh)

Flexibility (> 50 MWh)

Yes

Fuel Cells NO NO Average Average Average NO

Capacitors NOUser Power

QualityNO Average

Grid Power Quality

Grid Power Quality

- Electro-chemical.- Lead-acid gel, OPZ type.

- Lithium-Ion.- Flow.- Fuel Cells (Hydrogen).- Capacitors.

8

9

Module 1.4Inverters

Module 1.5Protections

10

Module 1.6Cables

11

Generation Side. Cable Loses.

Voltage Drop formula for Single Phase and DC Circuits.

VD = I × (2 × L × R / 1000)

Voltage Drop Calculation and formula for Three Phase system.

For 3 Phase 3 Wire system.VD = 0.866 × I × RVD = 0.866 × I × 2 × L× R/ 1000

For 3 Phase 4 Wire systems.VD = 0.5 × I × RVD = 0.5 × I × 2 × L× R/ 1000 Where,

VD = Voltage Drop in Volts.I = Wire Current in Amperes.R = Wire Resistance in Ohms (Ω) [Ω/km].L = wire distance in meters.

12

Generation Side. Cable Loses.

13

Module 2

Project Feasibility

Content

Module 1: Generation Systems


Module 3: EPC


14

Module 2.1Allocation and

Resources

Dimensioning and design of Off-Grid single user facilities.

Solar PV. Dimensioning and design of Off-Grid single user facilities.

Solar PV. Dimensioning and design of Off-Grid single user facilities. Load Profile

Load & Sizing

Periods Hours% Main

loadMain Load kW

Main Load kWh day

Main Load kWh Storage 3 days

Solar Generation Needed in kWp

Parameters 32 3 1,400

06.00 to 11.59 6.00 30 10 58 173

12.00 to 16.59 5.00 60 19 96 288

17.00 to 19.59 3.00 70 22 67 202

20.00 to 06.00 10.00 10 3 32 96

Totals 24.00 54 253 758 197.73


19

Module 2.1Allocation and

Resources

20


21

Wind. Dimensioning and design of Off-Grid single user facilities.

22

Wind. Dimensioning and design of Off-Grid single user facilities. Load Profile.

Load & Sizing

Periods Hours% Main

loadMain Load kW

Main Load kWh day

Main Load kWh Storage 3 days

Gross Generation kWh/Year*

Parameters 32 3

06.00 to 11.59 6.00 30 10 58 173

12.00 to 16.59 5.00 60 19 96 288

17.00 to 19.59 3.00 70 22 67 202

20.00 to 06.00 10.00 10 3 32 96

Totals 24.00 54 253 758 183,270

(*) Formula : (253 * 365 + (758 * (365 / 3))) = 183,270 kWh per year

23

Module 2.2Financial Feasibility

Solar PV. Dimensioning and design of Off-Grid single user facilities. Cost Approach

Cost approach

USD/kWp Calculated Size kWp Lifespan years

PV System 198 25.00 Panels 400.00 79,200 Mounting 350.00 69,300 Inverters 500.00 99,000 BoS & EPC 437.50 86,625

CAPEX 1,687.50 334,125 OPEX 15.00 2,970

Lifespan kWh Generated

CAPEX Lifespan OPEX CoE USD/kWh

CoE Calculation 6,930,000 334,125 2,970 0.05

USD/kWhCalculated kWh

TotalLifespan Years

Storage (Li-Ion) 350.00 758 25.00

CAPEX 265,440 OPEX 3.00 2,275

Lifespan kWh Delivered


CoE Calculation 2,306,800 265,440 2,275 0.12

Solar PV. Dimensioning and design of Off-Grid single user facilities. Cost Approach

USD/kWp Calculated Size kWp Lifespan years

PV System 66 25.00 Panels 400.00 26,400 Mounting 350.00 23,100 Inverters 500.00 33,000 BoS & EPC 437.50 28,875

CAPEX 1,687.50 111,375 OPEX 15.00 990



CoE Calculation 2,310,000 111,375 990 0.05

kW USD/kWh Calculated kWh Total Lifespan Years Lifespan Hours

Generator 115 150.00 2.44 16,000.00

CAPEX 17,280 1,536,000 OPEX 3.00 48,000 Fuel 0.99 0.25 380,160



CoE Calculation 1,536,000 17,280 428,160 0.29

Total CoE USD/kWh 0.34

Module 2.3Full Financial Model using NREL’s SAM

Solar PV. Dimensioning and design. Financial Model SAM.

Solar PV. Dimensioning and design. Financial Model SAM.

System Minimum Selling Price: 621,853 USD

Electricity Minimum Selling Price: 0.24 USD kWh

Client / Offtaker Accepts and signs contract ?

E P CStarts

Only 10 mins Wasted

Module 2.2Financial Feasibility

30

Wind. Dimensioning and design of Off-Grid single user facilities. Cost Approach

Cost approach

Size kW USD/kWCalculated Size

kWLifespan years kWh Turb Year

Wind Generator 60 183,280 25.00 172,778 Turbines 60 2,450.00 147,000 Civils 60 857.50 51,450 kWh Turb HourEPC 60 992 59,535 19.710 Ancillaries 60 645 38,698

Turb Rating kW

CAPEX 4,945 296,683 60.000 OPEX 70 105,000



CoE Calculation 4,319,447 296,683 105,000 0.09

kW USD/kWCalculated kWh

TotalLifespan Years Lifespan Hours

Generator 115 150.00 2.44 16,000.00

CAPEX 17,280 1,536,000 OPEX 3.00 48,000 Fuel 0.99 0.25 380,160



CoE Calculation 1,536,000 17,280 428,160 0.29

Total CoE USD/kWh 0.38 31

Module 2.3Full Financial Model using NREL’s SAM

32

Wind. Dimensioning and design. Financial Model SAM.

Module 2.4Project type

and EPC guarantees

34

Wind. Dimensioning and design. Financial Model SAM.

System Minimum Selling Price:XX XXX XXX USD

Electricity Minimum Selling Price: 0.XX USD kWh

Client / Offtaker Accepts and signs contract ?

SPV and PermitsFinancial Structuring

Only 10 mins Wasted

E P CStarts

35

Module 3EPC Content



Module 3: EPC


36

Module 3.1EPC

Design & engineering

37

Solar PV. EPC. Design.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1

2

3

4

2 mt

1 mt

Wind. EPC. Design.

39

Wind. EPC. Design.

40

Wind. EPC. Design.

41

Wind. EPC. Design.

42

Module 3.2Procurement

LogisticsProject

management

43

EPC. Engineering, Procurement and Construction.

Sourcing

Suppliers & Quotes

Payment Schedule

Construction Program

Contract for goods or services

44


Sourcing Suppliers

Specs

BoM & Quote

45

Solar PV. EPC. Engineering, Procurement and Construction.

Dear [supplier / contractor],

We have started the procurement process for a power plant in [location/area] to provide 24/7 uninterrupted power to a farming complex which is notconnected to the grid.The total consumption has been estimated to be 253 kWh per day, with an autonomy of 3 days, calling for a total storage capacity of 880 kWh. Themain power source will be Solar PV, with an installed capacity of 198 kWp.The Solar PV subsystem will provide power to the storage bank, which will deliver constant stable power to the facilities, while a diesel generator of300 kVA will be connected to the power management unit and available as backup.The power will be delivered to the facilities buildings in low voltage under trenching, while the Solar panels will be ground mounted in a single fieldwithin the facilities perimeter.The plant design adheres to all applicable IEC regulations, IEC H&S applicable standards and National Grid Code, therefore all components and worksshall meet those requirements and certifications. All required permits have been granted. Standard IEC and related environmental practices shall befollowed on all works, including logistics and site deliveries.This procurement stage will finish [P-date] and the site mobilization is scheduled for [M-date], while the commissioning is scheduled for [C-date],providing an overall duration of [days] working days.The contracting will be done according to FIDIC standards and bankable performance warranties will be required. Payment schedule based onmilestones completion, to be defined with the awarded [supplier / contractor],

We hereby, request your detailed quote, BoM (Bill of Materials) and delivery [and installation] schedule for the following components [and services]:

Panel field of 198 kWp in 330 Wp panels (600 panels in total) with proposed layout in landscape with 4 panels in height and 50 panels wide, forming 3tables. Distance between tables is 4 mt. Panels measure 1 mt by 2 mt, weighting 24 kg each.Tilt shall be 5 deg. North.All components and materials must be cut to measure and drilled in factory prior to HDG and/or coating/galvanizing.Ground mounting structures for mechanical pile-in, with main supporting pillars in factory HDG with a minimum coating of 90 microns.Tables to be continuous over the whole width.Panel supporting beams in Aluminum 6005 A T6.Panel clamps in AL 6005 A T6, with antitheft screws.All nuts and bolts of SST and self locking.Isolating washers between HDG and AL components.Mounting system to adequate for DC cabling along the structure.Inverter mounting under the panels in H frame of the same HDG or AL material. Inverter weight 70 kg.Delivery on site, installation and assembly.

Wind. EPC. Engineering, Procurement and Construction.

Dear [supplier / contractor],

We have started the procurement process for a power plant in [location/area] to provide 24/7 uninterrupted power to a farming complex which is notconnected to the grid.The total consumption has been estimated to be XXX kWh per day, with an autonomy of 3 days, calling for a total storage capacity of XXX kWh. Themain power source will be Wind, with an installed capacity of XXX kW.The generation subsystem will provide power to the storage bank, which will deliver constant stable power to the facilities, while a diesel generator of300 kVA will be connected to the power management unit and available as backup.The power will be delivered to the facilities buildings in low voltage under trenching, while the Wind generators will be ground mounted in a singlefield near the facilities perimeter.The plant design adheres to all applicable IEC regulations, IEC H&S applicable standards and National Grid Code, therefore all components and worksshall meet those requirements and certifications. All required permits have been granted. Standard IEC and related environmental practices shall befollowed on all works, including logistics and site deliveries.This procurement stage will finish [P-date] and the site mobilization is scheduled for [M-date], while the commissioning is scheduled for [C-date],providing an overall duration of [days] working days.The contracting will be done according to FIDIC standards and bankable performance warranties will be required. Payment schedule based onmilestones completion, to be defined with the awarded [supplier / contractor],

We hereby, request your detailed quote, BoM (Bill of Materials) and delivery [and installation] schedule for the following components [and services]:

Wind generators capable of providing XXX kWh in a standard 24 h cycle.Resource average is ~ XX m/s from XXX.Foundations ground is mainly composed of XXXX at foundation level and dominant Ph is XX, with a compressibility of XXXX kN and foundation depthand a lateral value of XXX kN.All metal components and materials must be cut to measure and drilled in factory prior to HDG and/or coating/galvanizing.When aluminum is to be used only 6005 T5 grade is accepted. When immersed/buried an additional resin coating is required.Incoterms 2010, FOB extended with inland and customs to delivery on site, installation and assembly.

47


Sourcing

Suppliers

SpecsBoM & Quote

Payment Schedule

Construction Program

Contract for goods or services

48

Module 3.3 Health & Safety

49


Health and Safety

• Personal protection gear is mandatory inside the works area for ALL people. You and visitors included.

• HiVis vests are mandatory for ALL people while on-site, either in works area or not.

Mandatory H&S gear for works area:• Hi Vis vest.• Safety boots or shoes.• Helmet.• Safety Glasses or Googles.• Work gloves.

Additionally,• Ear covers or earbuds when close to noisy areas.• Electric insulation Gloves when works near life wires.• Electric insulating footwear when near life equipment.• Back & waist protection band when lifting weights.• Safety Knee pads when working involves kneeing.

WEARING THE H&S GEAR IS MANDATORY FOR EVERYONE. IMMEDIATE FIRE ANYONE FAILING TO DO SO.

50


Health and Safety

• DAILY SAFETY BRIEFING BEFORE WORK START IS MANDATORY FOR ALL PERSONNEL.

• SAFETY BRIEFING IS MANDATORY FOR ALL VISITORS PRIOR ENTERING THE SITE AND THE WORKS AREAS.

• THE DAILY SAFETY BRIEFING MUST INCLUDE UPDATE OF ALL WORKS BEING CARRIED ON THAT DAY IN EVERY AREA AND THE STATUS OF ANY HAZARDOUS ENVIRONMENT IN ANY AREA OF THE SITE.

• ALL PEOPLE MUST SIGN THE ENTRY AND EXIT FROM THE SITE.

• ALL PEOPLE MUST SIGN THE H&S LOG AFTER THE BRIEFING AND BEFORE ENTERING THE SITE AND THE WORKS AREA.

• ALL MACHINERY MUST BE CHECKED FOR FULL SAFETY OPERATION EVERY DAY BEFORE BEING USED.

• INCOMPLIANCE WITH H&S RULES MEANS EXPULSION.51

Module 3.4Construction

Module 3.4Construction

53

Module 3.5EPC

ConstructionGroundworks

Site preparation

54

Module 3.6EPC

ConstructionGroundworksCabling and trenching

58

Module 3.6EPC

ConstructionGroundworksCabling and trenching

59

Generation Side. Cable Installation.

Whole set of manual and semi automatic cable pulling equipment.

Classic trenching and pulling. Inefficient & expensive

All in One – RentalAutomatic trenching and pulling machinery. They dig the trench, remove the soil, lay the cables, cover them, lay the safety tapes, close the trench and compact the soil.

The big units can do 20 km per day. 60


61


Quality with low budget – OK! Quality & clean– OK! Luxury – OK!

UNACCEPTABLE

These are considered engineers professional negligence in many countries

62

Generation Side. General Foundations.

Quick & easy installation, no specialized labor,Warranty by manufacturer.Cost & time efficient.Easily install 3 per day.

63


67

Module 3.7EPC

ConstructionMechanical

Module 3.7EPC

ConstructionMechanical

69

Module 3.8EPC

ConstructionElectro-

Mechanical


Panel installation is a critical and delicate process.

Teams of 2 to 4 people are needed.

On 3rd and 4th panel part of the team will have to stand in a small scaffolding structure.

The lower panel always goes first and has to be perfectly fitted and aligned.

The bolting is done ONLY with power tools with torque settable drivers. The panel manufacturer will provide the right number of Nm torque.

Any broken panel must be put aside to avoid stumbling on it and injuries.

Module 3.9EPC

ConstructionWeather station

Module 3.10EPC

Electrical works & testing


80

Solar EPC. Engineering, Procurement and Construction.

Module 3.11EPC

Electrical works & testing

Solar EPC. Engineering, Procurement and Construction.

Module 3.8EPC

ConstructionElectro-

Mechanical

84


85


86

Wind. Engineering, Procurement and Construction.

Module 3.9 EPC

Completion Hand Over

88

Wind. Engineering, Procurement and Construction.

Module 3.12O.M.

Solar O&M. Operation and Management.

Module 3.10O.M.

92

Module 4Transmission

and distribution models

Content



Module 3: EPC


93

Mini Grids vs Grids. Introduction.

=

~

~

Mini Grid

“Full” Grid

~

=

94

Mini Grids vs Grids. Introduction.

=

~

~ =

=

=

~

~=

=

Mesh Interconnected ClusteredMini Grid.

Interconnections are below 66 kV to avoid the cost of substations.

All generation and all consumption is shared over the whole integrated grid providing a self balanced operation.

95

Mini Grids / Clusters with DER Architecture.

1. Solar PV Plant2. Inverter Grid Forming3. Inverter/Charger & Controller

4. Storage5. Diesel genset as backup.6. Wind generation and/or others.

96

Mini Grids / Clusters with DER Architecture.

=~

=

=~

=

=~

=

97

Power Plants. Forms of Contracts.

Module 4.4 Regulation

99

Regulation.

100

hydrocarbon 25% reduction in energy intensity of gdp...

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