implementation framework for enhancing distributed solar ...€¦ · 1. staad pro certification 2....

Implementation Framework

for Enhancing Distributed

Solar PV Quality and

Safety for India

MNRE-USAID PACE-D 2.0 RE Program January 21, 2020

NREL | 2

Quality and

Safety Importance in DPV

On the field

3

Importance and Relevance of Quality and Safety aspects in DPV

Stakeholders’ Confidence

Utility Planning Revenue Loss to

Investors

Early Retirement of Systems and Disposal Woes

Accidents and Loss of Life

Key requirements for Quality & Safety Infratructure in DPV

Significant work at policy & regulation level; quality still one of the key concerns

MNRE

• List of Component Standards for all DPV

• Approved List of Models and Manufacturers

• Solar Pump Specifications announced in July 2019

SECI

• Model Tender Document for DPV

• Technical Specifications for Components and O&M Procedures

CEA

• Grid Connectivity Regulations

• Safety Regulations for DPV and Meters

SERCs

Technical Specifications in the Regulations

List of Standards for all components

SNA

• Adoption of MNRE guidelines and standards

• Independent Inspection Requirements (GEDA)

CEI

• Detailed procedures for SLD and actual installation approvals (Karnataka)

• Standard SLDs with all component specifications (Kerala)

Discom

• Meter Specifications based on Capacity and Consumer Type

SCGJ

Training and Certification of Discom Grid Engineers in various states & solar PV Entrepreneurs & Installers

Quality is a major challenge for the solar industry – which includes the

solar rooftop & distributed solar PV sector as well

Studies on Quality in India by PTB, UL and NISE say so………

• Pilot Study on Quality Aspects of PV Plants in India – By PI Berlin, September 2017

• All India Survey of Photovoltaic Module Reliability: 2014/16//18 – NCPRE, IIT Bombay & NISE

• UL Engineering challenge 2015 – Team 1

• UL Engineering challenge 2015 – Team 2

And these observations were reinforced through observations on the ground

Common findings from these Reports ….. and observed on ground

Solar Modules Quality -

varied quality from different/

same suppliers

Solar module

Performance Issues –

early degradation, micro-

cracks, PID, snail trails

Safety & Protections – Faulty

earthing, insufficient LPS, underrated

fuses and SPDs, disregard for fire

handling systems

Installation methods – partial

shadows on array, long runs of

DC cables, loose connections,

corrosion in structure

8

Commissioning – absence of independent inspection & lack

of commissioning tests

Performance – lower energy generation, intermittent

monitoring/ lack of timely follow up on corrective actions

O&M – inadequate maintenance, no schedule for

preventive maintenance

Documentation – absence of proper documents with customers,

planning/ design documents not shared with customers

NREL | 9

Methodology

of the Study

Methodology for the Study

Background research – Indian and Global

studies

Stakeholders Interviews

- In-person

- Telephonic

- Written responses

Explore Best Practices and

solutions in other countries

Derive possible solutions list with

their characteristics

Share and explore recommendations with stakeholders

Support implementation of

recommended solutions

NREL | 11

Study

Findings

t

The Distributed Solar PV Project Development Chain

Site Preparation

Erection of Structure

Wiring, Inverter & Safety

Module Installation

Commissioning O&M

Installation Stage

Design Quality (15%)

1. Fasteners (15%)

2. Handling of Modules (5%)

3. Earthing and Protections (5%)

4. Rest (10%)

The Distributed Solar PV Project Development Chain – 3 distinct phases -

surveys & literature show that each distinct phase has specific issues

1. Array Layout (7%)

2. String Inverter Mismatch (3%)

3. Access to Site (3%)

4. Rest (2%)

1. Modules (15%)

2. Structures (15%)

3. Junction Boxes (10%)

4. Rest (10%)

Components

Quality (50%)

Installation & O&M Quality (35%)

Issue definition Frequency Impact Respondent

(%)

Part or full shadow on the array throughout the year or some days of the year

H H 60

Inclined array on super structure or on sloping roofs looks aesthetically good but difficult to clean and maintain and repair

H M 75

Wrong enclosures of JB / SCB / DCDB / ACDB H H 70

Under specifications of protection devices like isolators, MCBs, MCCBs H H 60

Structure not able to withstand high wind pressure due to wrong material, loosely fixed members and modules, wrong design; not suitable for particular wind zone according to the standard

H H 90

Provision of insufficient (or nil) working space in form of walkways, railings, staircases, lifelines

H H 60

Inadequate earthing provision H M 80

Over estimation of energy H H 70

Over emphasis on capital cost H H 70

Key Findings - Design

Array layout to conforms to shadow analysis drawing – check drawing with actual layout

PV Syst/ PV Sol reports should be used to verify proper – on site matching – post installation check

1. Pathway next to array for R&M 2. Access to modules – without

specialised equipment 3. Provision of lifeline for safety

Array

Layout

(50%)

1

String

Inverter

Matching

(20%)

2

Site

Access

(10%)

3

Tests/ check points to address these key highlighted quality & safety issues problems

Design

Issue definition Frequency Impact Respondent (%)

Mild steel used for structure - rusting (even with anti rust paint)

H H 70

Galvanizing in GI not uniform, not of required thickness; leading to corrosion

H H 70

Low gap between ridge of the corrugated metal sheet roofing and module back surface; increase in module temperature

H H 60

Too thin structure components (angles, tubes, squares, C or I sections) resulting in warping and bending of structure

H M 70

Structure Certificate not submitted; Certificate is incomplete; Certificate does not serve the purpose

H M 70

Poor quality components (cells, EVA, backsheet, JB, etc.) used in module manufacturing

H M 90

Missing module certificates (or invalid / mismatching) H M 70

Key Findings - Components

• STAAD Pro Certification • Boundary layer wind tunnel test • Material treatment

• Bill of Materials • Acceptance Testing • Flash Test (At factory) • EL Test (At factory) • LID (At factory) • Visual Inspection (At factory) • Thermal Imaging (At site)

Integrate with Inverter or test all protection devices


Components

Structures

(100%)

1

Modules

(50%)

2

Junction

Boxes

(100%)

3

Issue definition Frequency Impact Respondent

(%)

Lack of inspection by qualified and experienced engineer leaves many areas for improvement that cannot be rectified later

H H 90

Structure components, hardware and fixing to the roof H H 90

Walkways, railings, earth pits are not checked H M 90

CEIG / Discom inspection does not completely cover PV side aspects

H M 70

Handling of modules prone to accidents and unseen module damage

H M 60

Modules tightened at different torques producing stress on modules and exposing to damage under high wind conditions

H M 70

In O&M SPDs not periodically inspected to check if these have been sacrificed and need replacement

H M 60

Key Findings – Installation and O&M

Check fastener design with finite element analysis or similar

Thermal Imaging Test – and compare results with flash test

1. Lightening arrestors effective radius covering array

2. No. of Earthing's – Min. of 3 for each system

3. Soil Resistivity in each Earth pit < 5 Ohms


Installation

Fasteners

(50%)

1

Handling

of Modules

(20%)

2

E&L

Protection

(100%)

3

These Quality & Safety issues are more commonly observed in

• 70% systems under Capex model

• 49% non-industrial customers

• Only 11 EPC players had market share higher than 1% of total 2018 market of 1,836 MW

Key factors behind low quality and unsafe solar PV systems in India

Huge focus on capital costs rather than

LCOE

Lack of knowledge

amongst EPC & installers – no

eligibility criteria

Customer ignorance

No push back on EPC due to

low quality work &

performance

Gaps in existing quality & safety

standards

Lack of proper inspection during and

after installation

Absence of mandatory

requirement of Supervision and Audit

NREL | 22

Potential

Solutions

NREL | 24

NREL has worked with the international community to help develop the IECRE system for certification, at each step of a PV system’s life.

Design

Qualification

Substantial Completion

Annual

Performance

Asset Transfer

Project Timeline

Technical standards Certificates for system

IECRE already issues certificates

Updated IEC technical standards feed into the new IECRE system.

OD 403, “Plant Design

Qualification Certificate”

OD 402, “Annual PV plant performance

certificate”

OD 401, “Conditional PV

project certificate”

OD 405-1, -2, -3 Module QMS

OD 410-1, -2, -3 QA for Installation and O&M

OD 404, “PV Plant

Assessment”

Learnings from US experience – NREL

Learnings from Australia experience – Clean Energy Council

Clean Energy Council - promotes awareness, thought leadership and regulation for clean energy

businesses in Australia. The regulation is provided through a system of endorsement and accreditation.

Accreditation is available to individual installers and designers.

• There are now around 4,500 Clean Energy Council accredited installers in Australia • Rigorous application process for accreditation, use of CEC approved products and

CEC compliance procedures

CEC Approved Solar Retailer -

1st stop for customers looking to buy solar from a certified company. These retailers are signatories to the CEC Solar Retailer Code of Conduct - designed to stamp out unethical practices in the industry including:

• Misleading claims & advertising regarding performance, size of solar PV system, government incentives, suitability of PV systems and future electricity bills;

• Not taking responsibility for the PV system including product warranties and workmanship;

• Sub-standard installation work; and • Retailers not taking responsibility for subcontracted parties acting on their

behalf

CEC Accreditation

Potential Recommendations

Information Database – Consumers

& Developers

Voluntary System and Installer Certification,

with Third-Party Inspection

Mandatory System and Installer Certification

Require Mandatory Third-Party Inspections

Update Guidelines from the MNRE

Create a Rating System of Developers Based on

their Quality and Performance Records

Create Guidelines for New EPC Companies

and Installers

3rd Party Module Quality Assurance

NREL | 27

Select

Recommendations

The Distributed Solar PV Project Development Chain – Path to Solution Set (1)

Pre-installation Stage Modules Every

Project

Installation (Pre-

commissioning) E&L

Protection Evaluate appropriateness

of Safety equipment(s) Agency concerned

with safety

Every Project

Site Access Evaluate Safe access/ lifeline to system

Agency concerned with safety

Every Project

Junction Boxes Evaluate Quality of Safety Equipment

Agency concerned with safety

Every Project

Structures Evaluate Quality of

Design Agency concerned

with safety Every

Project

Independent Technically Qualified Agency

Evaluate Quality of Input Material & Production

The Distributed Solar PV Project Development Chain – Path to Solution Set (2)

Post Commissioning

Array Layout Evaluate Array layout vis a vis

layout in shadow analysis Independent Technically

Qualified Agency Sample – Post Eval

String Inverter Matching

Evaluate String Current matches Inverter MPPT


Sample – Post Eval

Handling of Modules at Site/ Transport

Evaluate quality of modules at site – compare with Module tests analysis



Structures Structural Safety Independent Technically Qualified Agency


The Distributed Solar PV Project Development Chain – Key quality & safety issues &

potential solutions

Stage of Project

Development

Key Issue Potential Solutions

Design

Array Layout Array layout to conforms to shadow analysis drawing – check drawing

with actual layout

String Inverter

Matching

PV Syst/ PV Sol reports should be used to verify proper matching – on

site matching – post installation check

Site Access Pathway next to array for R&M; Access to modules – without

specialised equipment and Provision of lifeline for safety

Components

Structures 1. STAAD Pro Certification

2. Material treatment

Modules

• Bill of Materials

• Acceptance Testing

• Flash Test (At factory)

• EL Test (At factory)

• Visual Inspection (At factory)

• Thermal Imaging (At site)

Junction Boxes • Integrate with Inverter or test all protection devices

Installation E&L Protection




Handling of Modules 1. Thermal Imaging Test – and compare results with flash test

Electrical Safety

Assurance

Module Quality

Certification

Vendor Rating

NREL | 32

Select

Recommendations 1 –

Module Quality

Certification

Module

Quantitative

Data driven

Time based

The Distributed Solar PV Project Development Chain –

Basic Design Principles for Solution Sets

Basic Design

Principles

Performance Based

Modular

The Distributed Solar PV Project Development Chain – Implementation Framework for

Module Quality Assurance (1)

Why Module Quality Assurance: 1. Modules reported as one of the three main components with quality issues 2. Modules make up almost 50% of the cost of the system - impact of bad module quality can be loss of upto 50% of

project output 3. Module quality, even from same suppliers has shown variations

• Manufacturing in line inspection carried out by large project developers (by themselves or inspection agencies)

• 1st hand checking of Bill of Materials of Module • 1st hand checking of Module Component Quality (EVA

back-sheet, Cells, JB etc.) • Observation of in line tests – Flash & EL tests • Post sale warranty support available to large

developers due to large repeat orders

• Procurement through dealers and agents (sometimes not even authorised)

• Small order sizes – no traction with manufacturer • High transaction costs of in line inspections • Lack of proper documentation from manufacturer

not available • Ignorance around quality challenges with module

How is module quality managed for large MW sized projects

Why is module quality assurance not available for small kW sized projects

Module Manufacturing

Module Transport & Storage

Module Installation

Material for Module Manufacture

Check BoM Acceptance Tests

• Visual Inspection • Flash Test • EL Test

Certification by 3rd Party Agency – certificate with test results *e.g. UL, TuV etc.

Distribution Utility Discom to check

Certificates provided by 3rd Party Agency

Review of acceptance test results - Visual Inspection, Flash Test, EL Test & LID Thermal Imaging Test by Vendor Rating Agency

Vendor Rating Agency

3rd Party Module Quality Certification Agency

Potential Module

Aggregator/ Distributor


Module Quality Assurance (2)

Distributed Solar PV Project Development Chain –

Pathways to achieving improved quality in Modules

Design of Module Aggregation Methodology

Identification of Agency for Aggregation(s)

Module Testing & Certification Protocol

Creation of Module Procurement Aggregator(s)

1) Quality Checks by inspection agencies 2) Aggregation of demand from small developers/ EPC

Distributed Solar PV Project Development Chain – The Opportunities & Challenges

in Module Quality Certification

• Limited to components & that too mostly modules

• No input on system design & installation

• No mandate & no institution working on this aspect at present

Challenges

• Brings economies of scale

• Lower transaction costs & low cost of quality assurance

• Specialised agency for purchasing key components

• Improved quality assurance

Opportunities

NREL | 38

Select


Safety Checks

through Distribution

Utility


Safety through Discom (1)

What are the challenges to ensuring safety in Distributed PV Installations: 1. Safety checks by in large ignored – mostly a mandate of Discom or CEI 2. Some safety features not mandated 3. Consumer ignorant about safety – accepts compromises for cost cutting

• BESCOM – Interconnection Process mandates use & audit of safety features

• Kerala CEI – Published standardized Single Line Diagrams including safety devices specifications

• Some state regulations also mandate safety features in solar rooftop systems

• IECRE – NREL’s standards for rooftop systems operations document includes safety features.

• Only Discom responsible for checks & inspection of every rooftop project – i.e. the Discom

• Solar rooftop not a priority for Discom Enginers • Most Discom Engineers lack understanding of

solar rooftop & consequent safety issues – lack of training

• Site inspection & report generation time consuming for Discom Engineers.

• Lack of tools to fulfil the role

Few Examples of Safety in Distributed PV

Why is safety not a priority for small kW sized projects


Safety through the Discom (2)

Responsibility of Discom

Key Challenge – Proper verification of Quality of Work

Verification of Inspection Reports of CEIG/ Discom by


Easy to Fill Checklist based Tool

on Smart Phone

Training & Capacity Building Standard Operating Procedures

for Safety Documented in Regulation

Junction Boxes E&L Protection Site Access STAAD Pro

Certification by Structural Engg.


in Safety Assurance through Discom

• System Quality – of limited interest for Utility

• Limited capacity of utility personnel

• High bandwidth requirements from utility personnel

Challenges

• Comprehensive coverage – as all sites visited

• Deep understanding & concern about safety issues

• Lowest transaction cost • Concurrent monitoring

Opportunities

NREL | 42

Select


Vendor Rating

The Distributed Solar PV Project Development Chain – Implementation Framework for the

Vendor Rating Framework (1)

• To provide a mechanism to evaluate

quality of onsite work (design,

components, installation) & performance

of systems

• To provide a comprehensive evaluation of

vendors – infrastructure, manpower,

systems & tools

• To generate performance data of various

components & systems

• A single point of reference for

stakeholders (consumers, FI’s &

developers) to identify quality vendors

What is a Vendor Rating Framework?

• Rating will be voluntary & based on benefits

in business that come to vendors with

ratings

• Framework will look at Vendor systems and

processes as well as sample installations to

arrive at a rating score

• Rating will be time bound and rolling in

nature

• Sampling of systems will allow vendors to

continuously improve ratings

• Ratings will be available to vendors to

advance business interests

How will the vendor rating

framework work?

The Distributed Solar PV Project Development Chain – Implementation Framework for the Vendor

Rating Framework (2)

A specialized agency like CII, TERI, GERMI

etc. with:

• prior experience in undertaking ratings

• independence

• a pan India presence

• excellent working relationship with

industry

• domain knowledge & industry

experience

• ability to train manpower & procure

equipment

Agency will develop a detailed framework for

rating vendors and a business model to make

this work financially viable

Who will be responsible for Vendor Rating?

Vendors:

Tool for business promotion; and

Benchmarking & improvement tool

Developers:

Tool for identifying quality vendors (EPC/installers);

Performance of systems on ground;

Lower transaction costs; and

Lower interest debt

Consumers:

Enhanced quality systems;

Cost competitiveness & Vendor comparison;

Consumer education & awareness; and

Lower interest debt

Bankers:

Quality of vendors & systems; and

Performance of systems on the ground

What are the benefits of a Vendor Rating

Framework for key Stakeholders

The Distributed Solar PV Project Development Chain – Quality Assurance

through Vendor Rating Agency (3)

Quality Measurement • Plant Performance • Module Tests – Thermal

Imaging • Array Layout Quality • String Inverter Design

Quality • Fastener & Structure

design Quality • Soil Resistance Test


Vendor Rating Framework

Compliance Functions • Module Test Reports • STAAD Pro Report &

Galvanisation Compliance • Fire Safety Regulations • Protection Device

Compliance • Provision of Earthing &

Lighting Protection

Distributed Solar PV Project Development Chain – Pathways to achieving improved Vendor

Rating

Identification of an agency for managing Vendor Rating Framework

Key parameters for Rating Vendors

Marketing & Usability of Rating

Framework

Training Rating Agency/ Rating Professionals

Rating Methodology

Rating framework for EPC/ Vendors

IT Application for Consumers for Vendor/ System Selection

Database of Rated Vendors/ Systems for

Banks & FI’s

Performance Database Creation

Awareness on Quality amongst Consumers/

FI’s


in implementing a Vendor Rating Framework

• Can be undertaken on sample basis

• Will be costly – need a business model

• Ex-post and not Ex-ante • Need to simplify rating system for

consumers

Challenges

• Ability to rate components, design & workmanship

• Comprehensive Assessment • Trained manpower • Appropriate Instruments • Detailed Analysis of each site

Opportunities

Next Steps

• Develop Implementation Plan for Recommendations

• Identify Vendor Rating Agency

• Design Rating Framework

Design Stage

• Create framework for module quality assurance by 3rd Party

• Modify Utility Procedures to include safety & quality better

• Develop outline & functionality for an app for utility engineers

Implementation Stage • Launch Vendor Rating Framework with Agency

• Backstop agency in rolling out the Vendor Rating Framework

Support Stage

Thank You for Your Time &

Attention

Cre

dit

: Ph

oto

sto

ck

The Distributed Solar PV Project Development Chain – Key Quality & Safety issues, their

impact on Project Returns & Potential Solutions

S. No. Stage of Project

Development

Key Issue Potential Solutions

1

Design

Array Layout Array layout to conforms to shadow analysis drawing – check drawing with actual layout

2 String Inverter Matching

PV Syst/ PV Sol reports should be used to verify proper matching – on site matching – post installation

check

3 Site Access

Pathway next to array for R&M; Access to modules – without specialised equipment and Provision of

lifeline for safety

4

Components

Structures 1. STAAD Pro Certification

2. Material treatment

5

Modules

• Bill of Materials

• Acceptance Testing

• Flash Test (At factory)

• EL Test (At factory)

• LID (At factory)

• Visual Inspection (At factory)

• Thermal Imaging (At site)

6 Junction Boxes Integrate with Inverter or test all protection devices

7 Installation E&L Protection




8 Handling of Modules 1. Thermal Imaging Test – and compare results with flash test

The Distributed Solar PV Project Development Chain – Approach to Implementation

Framework Development

implementation framework for enhancing distributed solar ...€¦ · 1. staad pro certification 2....

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