Wayne A. Dunn, PE, PEng

Catching Rays Solar PV Commissioning

AIA Quality Assurance

The Building Commissioning Association is a Registered Provider with The American Institute of Architects Continuing Education Systems (AIA/CES). Credit(s) earned on completion of this program will be reported to AIA/CES for AIA members. Certificates of Completion for both AIA members and non-AIA members are available upon request.

This program is registered with AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product.

Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.

This presentation will outline the commissioning process for solar photovoltaic systems and cover lessons learned from a recent 150 kW (nominal) construction project in the state of Florida.

Commissioning providers, owners, designers and construction teams working with these special systems can apply lessons learned from these experiences to benefit their own projects.

Course DescriptionCourse Description

At the end of this session, participants will be able to apply lessons learned in the following categories:

1. Solar Energy Profile2. Risk Management During Design3. Quality Assurance During Construction4. System Testing & Performance Verification5. Technology Transfer / Operation & Maintenance6. Solar PV ---future

Learning ObjectivesLearning Objectives

Catching Rays

Catching Rays

Passive Solar

Solar Heating & Furnace

Concentrated Solar

Solar PV Types & Efficiencies (NREL)

Solar PV Applied

Photovoltaic Project OverviewFL Dept. of Health

State Owned Campus 17 buildings ~1.7 M Sq. Ft.

ARRA funded $1,340,982

150 kW (Nominal) Fixed 21 Angle South-Facing 2 Sub-Arrays

Suniva ART 240 Modules Satcon PVS 75 kW

Inverters Remote Monitoring System

Project Design Criteria

Decision Cycle Which Building? How much roof? Watts / Panel Buy America Inverter Locations Lightning Protection Equipment Installation

Roof Access Elevators vs. Stairs

Project Metrics

Solar Power System Array Breakdown1 Panel (Module)240 W

60 Cells

1 String3120 W

13 Panels

1 Group18.7 kW

6 Strings(78 panels)

1 Sub-Array75 kW

4 Groups(24 Strings)(312 Panels)

Total System150 kW

2 Sub-Arrays(8 Groups)(48 Strings)(624 Panels)

Project Design Criteria

System Design Watts / Panel MFG / UL Requirements Panels / String

Max System Voltage: 600 VDC UL- 5% Voc Tolerance- -0.332 (%Voc / F) Temp. Coeff. vs. STC- 37.2 Voc / Panel

581.8 VDC at Record Low 13 Panels / String

Strings/Combiner Wire Sizing

Design Phase Cx - Overview

Recommendations Factory Testing

Modules Not inverter

Cx Requirements Documentation Testing Methodology Meters / Verification

Remote Monitoring Weather Station Software

Labeling / ID

Design Phase Cx Factory Testing

Recommendations Confirm the Following:

Production Capacity Manufacturing Processes

- Cell here, modules there Quality Control Processes Proof of Performance

Design Phase Cx Solar Panel Installation

Design Considerations Efficiency Size Panels per String Panel Mounting

Clamps Height Above Roof

Design Phase Cx Interface

Communications Remote Monitoring

Software Status / Maintenance Weather Performance

- Predicted- Actual

Dashboard

Design Phase Cx Communications

Challenges Department IT

Infrastructure Coordination

Contractor Submittals What are we Getting? What format?

Implementation When are we Getting It? Hardware Features Lacking Who Configures Software? Not my Responsibility

Design Phase Cx Weather Station

Weather Station Panel Cell

Temperature Ambient Temperature Solar Irradiance

(W/m2) Wind Speed / Direction Remote Monitoring

Design Phase Cx Weather Station

Challenges Communications Application

Solar Radiation Sensor Angle- Installed Horizontal

UV / Sun tan application- No adjustment

Jury rigged angle Cell Temperature Sensor

- Installed Loose Under Panels No Relative Humidity No Barometric Pressure

Design Phase Cx Labeling / Identification

Design Approach Clear and Consistent

Individual panels Strings String Groups Inverters

Challenges Panels not labeled Combiner Boxes not labeled As-Built vs. As-Labeled

String 4-A on Inverter B?

Construction Phase Cx Submittal ReviewEquipment Submittals

PV Modules Inverters Combiner Boxes Re-Combiner Boxes Weather Station

Software Submittals Remote Monitoring Dashboard

Coordination Submittals Equipment

Labeling Layout

Factory ReviewFactory Inspection

Buy America Confirmed Made in China Assembled in US

Comfort Level Production Capacity Factory Quality Control Quality Assurance

Technical Insight Performance Verification Troubleshooting

Construction Phase Cx Installation VerificationInstallation Verification

DC System Wiring / Conduits

- UV / Weather Protection- Clamp Installation- Check Torques

Solar PV Panel Mounting- Ponding- Clamp Installation

Combiners / Recombiners Disconnects

Oh yeahSafety

Construction Phase Cx Installation VerificationInstallation Verification

AC System Inverters

- 4 vs. 5-Wire- Ethernet Comm Board

Wiring / Conduits Disconnects / Shunt Trip

Weather Station Communications Lightning Protection

No UL Certificate

Construction Phase Cx Performance Verification

Construction Phase Cx Performance Verification

Technology TransferSystems Manual

Provide O&M Staff System Level Understanding Useful Information Instructions Diagrams

Record Documents Content Turnover Schedule

Training Content Scheduling / Coordination Agenda

Technology Transfer I am SO confusedRecord Documents

As-Builts not latest drawing revision.

Missing O&Ms and Warranties. Afterthought.

Trainingin spec?!! Not Coordinated. Agenda not Approved. Inadequate

No Software Training

Not worth the fight.

DC-to-AC Derate as Advertised?

77% Typical (NREL.gov)

88% DOH

Why? Module Tolerances Inverter Losses Wiring Losses Soiling System Availability

O&M - Expected vs. Actual Performance

O&M Ongoing Performance Verification

Why Bother? Solar Panel Warranties often Performance Based Predictive Maintenance Maximize Energy Savings

O&M Lessons Learned

Whos the Boss? Help Owner Determine Key O&M Staff

Building Manager vs. Electrical Group

Develop Preventative Maintenance ProgramSystem Integration

Too Many Systems to Monitor Multiple Solar System Web Interfaces Not integrated to main campus BAS.

BAS / EMS Critical Information Status Key Power Information Weather Data Useful for HVAC Control

O&M Ongoing Performance Verification

O&M Ongoing Performance Verification

O&M Ongoing Performance Verification

O&M Solar Power Dashboard

Solar Future(dead, dying or retrenching & growing)

Major Closures for First Solar, SunpowerSteven Leone (renewableenergyworld.com)

Despite Solyndra's Death, the Future of Solar Energy Is SunnySteven Pleging CEO/ President Quantum Solar (Huffington Post)

Solar Future(tipping point)

McKinsey & Company: Solar Power: Darkest before dawnApril 2012 : Krister Aanesen, Stefan Heck, and Dickon Pinner

Solar Future(tipping point)

Cool Concentrator?(www.coolearthsolar.com)

Solar Roadways?(www.solarroadways.com)

Planes, Trains & Automobiles?

Give Credit Where Credit is Due

Aaron Fancher, PE (www.pegengineering.com ) Troy Strand (www.indenergysolutions.com ) Blake Gleason, PE (www.sunlightandpower.com ) Adrian Brunoi (www.solarsource.net ) Mckinsey & Co. (www.mckinsey.com ) All who freely publish on the WEB

Wayne A. Dunn, PE, PEng

E.W. Dunn

waynedunn@ewdunn.com