comissioning report msm new
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Comissioning Report MSM NewTRANSCRIPT
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Installation & Commissioning Report
128 KW Grid-Tied Solar Power Plant
Installed at: Masood Spinning Mill (MSM) Kabirwala
Installed By:
Premier Energy (Pvt) Ltd.
Solar Power plant Commissioned on: 24 August 2015
Signed By:
____________________ ____________________
Mahmood Ahmed Fazal Yasin
Manager Technical Operations Manager Electrical
Premier Energy (Pvt.) Ltd Masood Spinning Mill (MSM)
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Background
Solar power in Pakistan is most suitable solution because of energy crisis, load shedding and power crisis.
Pakistan covers 796,095 square kilometers of land between latitudes 24 and 36north and longitudes 61
and 76 east. At present, it faces serious energy problems: 95 per cent of its electricity generation comes
from hydropower, which becomes less productive during the driest, hottest months of the year and cannot
keep pace with the sharp rise in energy demand. Also, about 70 per cent of the population lives in some
50,000 villages dispersed around the country. Many of these villages are far from the main transmission
lines of the national grid and, because of their relatively small populations; it is usually not economically
viable to connect these villages to the grid. Solar energy, on the other hand, has excellent potential in
areas of Pakistan that receive high levels of solar radiation throughout the year. Every day, for example,
the country receives an average of about 19 Mega Joules per square meter of solar energy. Hot, sunny
climate, long daytime hours and unstable grid power generation makes solar energy an ideal solution for
Pakistan. Kabirwala, due to its more summer hours, is ideal for solar power plant.
Before start of this project at Masood Spinning Mill (MSM) , we utilized meteorological data, using
temperatures, radiation scores and longitude and latitude readings to design the perfect solar energy
system customized according to the requirements of our clients. Air ducts roof were selected for
installation due to easy access to LT Room of Unit 2.
Project Details:
It is a 128KWp Grid tied project and consist of four grid tied ABB inverters TRIO-27.6-TL-OUTD.In
This System total 504 panels are used. 100 panels of Canadian solar and remaining 404 panels of
SunTech Solar are used. Inverter 1, 2, 3 is fed by DC input of 32.13 KWp that means 126 panels of 255W
for each inverter and remaining 4th inverter fed by DC input of 31.63KWp that means 100 panels of
250W and 26 panels of 255W. Each inverter consists of two MPPT controllers. Three strings of 21 panels
each are connected to each MPPT and in this way 6 strings are connected to each inverter. So we have a
total of 24 strings for 4 inverters. As the open circuit voltage of the panel is 37V, so the string voltage is
more than 700V in peak hours, suitable for MPPT operation in independent mode.
The DC cable used for each string to inverter is 6mm and the inverter to grid AC cable is 95mm and the
support structure consist of galvanized coated iron. For protection AC and DC disconnect switch, DC
over voltage surge arresters and AC over voltage surge arresters and string protection fuses are available
for each inverter. Also on AC side ABB 120 Ampere 4 pole breaker is used for every inverter. The
inverters are grounded using 4mm cable and Main DB panels is grounded by 35mm earth wire and
connected with main LT room earth point for earth protection. A set of 126 panels is made and is
grounded with 4mm cable.
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Installed Equipment:
SR# Accessory Name Specs Quantity Total
01 Solar Panel (Poly) Suntech 255W 404 404 Panels
02 Solar Panel (Poly) Canadian 250W 100 100 Panels
03 Mounting Frames(Suntech) GI Adjustable 408 408 Frames
04 Mounting Frames (Canadian) GI Adjustable 100 100 Frames
05 Bolts for Panel fixing GI, 13mm,1 1112 1112 bolts 06 Nuts for Panel fixing GI, 13mm 1112 1112 Nuts
07 Washers for Panel fixing GI, 14mm 1112 1112 Washers
08 Bolts for Frames fixing GI, 13mm,3 1410 1410 bolts 09 Nuts for Frames fixing GI, 13mm 1410 1410 Nuts
10 Washers for Frames fixing GI, 14mm 1410 1410 Washers
11 Rawalbolts M8 (5/16) 1150 1150 Rawalbolts
12 Rawalbolts Washers GI 1150 1150 Washers
13 1 Core DC Cable 6mm,Pure cupper shielded
cable
405m 405m 1 Core DC Cable
14 2 Core DC Cable 6mm,Pure cupper shielded
cable
734m 734m 2 Core DC Cable
15 PVC Pipe 1 Popular Pipe 177 lengths 135 lengths 16 PVC Pipe 3 Popular Pipe 13.5 lengths 13.5 lengths 17 Earthing Wire frame to
frame 4mm single core 540 m 540 m
18 Earthing Cable 35mm From DB to Load
65 m 65 m
19 Flexible pipe 1 flexible pipe 8 bundle 8 bundle 20 Pipe joints, Bends, T joints 1 Popular Pak
Arab 100 pieces
of each item 100 pieces of
each item
21 Socket 1 Popular Pak Arab
150 pieces 150 pieces
21 Communication wire Networking cable
60m 60m
23 Communication Connector 485 to RS232 converter
1 1
24 AC wire 95mm 4 core shielded cable
Fast Cable
65 m 65 m
25 AC Breaker 80-100 A AC breaker ABB
4 4
26 Combined DB Panel Polarized coated iron
Set Set
27 Cable Duct 80 x 80 mm 48 Feet Cable Duct 48 Feet
28 Cable ties 8 PVC Cable Ties
13 Packets 13 Packets Cable ties
29 Regular tap PVC Regular Tap
8 Bundle 8 Bundle Regular tap
30 HT Tap HT Tap for Connections
1 1 HT Tap
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Solar Panel Commissioning Data
Solar Panel Technical Data:
Model: SCT STP255-20/Wem:
Company/Brand: Suntech Polycrystalline
Voltage Optimum: 30.8 Volts
Short Circuit Current: 8.76A
Open Circuit Voltage: 37.6V
Operating Module Temperature -40 C to +85 C
Maximum System Voltage 1000 V DC (IEC)
Maximum Series Fuse Rating 20 A
Power Tolerance 0/+5 %
STC: irradiance 1000 W/m2
Module temperature 25 C, AM=1.5
NOCT STP255-20/Wem
Maximum Power at NOCT (Pmax) 188 W
Optimum Operating Voltage (Vmp) 28.1 V
Optimum Operating Current (Imp) 6.68 A
Open Circuit Voltage (Voc) 34.7 V
Short Circuit Current (Isc) 7.12 A
NOCT: Irradiance 800 W/m2.
Ambient temperature 20 C, AM=1.5, wind speed 1 m/s.
Temperature Characteristics:
Nominal Operating Cell Temperature (NOCT) 452C
Temperature Coefficient of Pmax -0.42 %/C
Temperature Coefficient of Voc -0.33 %/C
Temperature Coefficient of Isc 0.067 %/C
31 Copper Sleeves 35mm Copper sleeves
18 pieces 18 pieces Copper Sleeves
32 Copper Thimbles 35mm, For Ac output Wire Connections
20 Pieces 20 Pieces Copper Thimbles
33 Grid Tied Inverter 27.6 KW Grid Tied Inverter
4 Two 27.6 KW Grid Tied Inverter
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Panel Installation Configuration:
Total Panels: 504
SunTech 255W: 404
Canadian 250W : 100
Total no of Strings: 24
Total no of panels per String: 21
Grid Tied Inverter:
Technical Data and Types:
Type code TRIO-27.6-TL-OUTD-S2X-400/JP
Input side:
Absolute maximum DC input voltage (Vmax,abs) 1000 V
Start-up DC input voltage (Vstart) 430 V (adj. 250...500 V)
Operating DC input voltage range (Vdcmin...Vdcmax) 0.7 x Vstart...950 V
Rated DC input voltage (Vdcr) 620 V
Rated DC input power (Pdcr) 28600 W
Number of independent MPPT 2
Maximum DC input power for each MPPT (PMPPTmax) 16000 W
DC input voltage range with parallel configuration of MPPT at Pacr 500...800 V
DC power limitation with parallel configuration of MPPT Linear derating from max to null
[800VVMPPT950V]
Maximum DC input current (Idcmax) / for each MPPT (IMPPTmax) 64.0 A / 32.0 A
Maximum input short circuit current for each MPPT 40.0 A
Number of DC inputs pairs for each MPPT 5
DC connection type Tool Free PV connector WM / MC4
Input protection:
Reverse polarity protection for inverter only, from current limited source, with max 2 string connected
Input over voltage protection for each MPPT - varistor 2
Input over voltage protection for each MPPT - plug in modular
surge arrester (-S2X version) 3 (Class II)
DC switch rating for each MPPT (version with DC switch) 40 A / 1000 V
Fuse rating (versions with fuses ) 15 A / 1000 V
Output side:
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AC grid connection type Three Phase 3W+PE or Three phase 3W+N+PE
Rated AC power (Pacr @cos=1 ) 27600 W
Maximum AC output power (Pacmax @cos=1) 27600 W
Maximum apparent power (Smax) 30000 VA
Rated AC grid voltage (Vac,r) 400 V
AC voltage range 320...480 V
Maximum AC output current (Iac,max) 45.0 A
Contributory fault current 46.0 A
Rated output frequency (fr) 50 Hz / 60 Hz
Output frequency range (fmin...fmax) 47...53 Hz / 5763 Hz
Nominal power factor and adjustable range >0.995 Adj 0.8 with max 30kVA
Harmonic Distortion of Current each
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Installation Installation of Solar Power plant with 128 KW Installed capacities was carried out in two stages.
Installation Phase 1
Before starting the work
Before starting the work our engineers compared the theoretical readings with the practical readings by
taking different short circuit test of SunTech panel (255W) at different tilt angles at Kabirwala.
They observed that the best output (8.3A) was achieved at tilt angle of 28 degree.
The panel orientation towards south was adjusted for maximum output.
A reference panel was set for the maximum output.
Panels installation were observed to be difficult because Air Ducts were 5 feet height from roof surface.,
Also it was too difficult to work during day time due to hot weather and working was then started at night
time and after that it was shifted at day time.
Panels installation
Work force for panel installation:
Two Engineers
Four Assistant Engineers
Two Technicians
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Installation started:
Four assistant Engineers and two technicians started panels mounting in the supervision of two Engineers.
Panels were properly fixed with galvanized frames and then the structure was mounted on the roof using
proper bolts. All 404 panels were mounted by the same manner. 100 panel of Canadian solar was already
installed.
Making strings:
Strings were made by connecting a set of 21 panels to achieve the desired DC voltage level for the ABB
inverter. In this way a total number of 24 strings were made from all 504 panels.
Cables and cable piping:
A 6mm cable was used to connect each string with inverter, the connection was properly punched and
then insulation tape was used to ensure the safety. The cables were laid in the PVC Pipe and trenched into
the room.
Installation Phase 2
In this phase the four on-Grid inverters of ABB, AC cable 95mm, Cable for grounding, DB Panel and
other necessary accessories were transported to Kabirwala.
Grounding:
All panels were grounded in four working days using 4mm cable. A set of 126 panels were made and was
grounded with 4mm cable and connected with main DB Panel earth wire .The inverters were grounded
using 4mm cable. Similarly the DB panel was grounded using 35mm cable and connected with earth
point of LT room.
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Inverters and DB installation:
The inverters were hanged on walls of the inverter room, two on each side of the room and beside of the
door DB Panel was hanged. The DB panel consist of 4 AC breakers, out of this four breakers were 80A to
100A (one for each inverter). The AC and DC cabling were done by proper PVC piping.
Checking polarity and string voltages:
The polarities of each string were then checked through multi meter and then male and female connecters
were connected to the positive and negative terminals of the strings accordingly. Meanwhile the string
voltages were checked at the same time it was observed 700 volts minimum in all 24 strings.
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Solar Panel String Voltages
The polarities of each string were checked in field and then in inverter room through multi meter and then
male and female connecters were connected to the positive and negative terminals of the strings
accordingly. Following were the voltages of the strings with cable nomenclature:
String Name Voltage in field Voltage in
Inverter Room
1. Inverter 1- 1 A 726.70 V 719.6 V
2. Inverter 1- 1 B 720.44 V 709.8 V
3. Inverter 1- 1 C 723.42 V 714.8 V
4. Inverter 1- 2 A 728.91 V 721.7 V
5. Inverter 1- 2 B 740.03 V 729.1 V
6. Inverter 1- 2 C 743.28 V 732.8 V
7. Inverter 2- 1 A 718.15 V 710.2 V
8. Inverter 2- 1 B 719.17 V 711 V
9. Inverter 2- 1 C 727.57 V 719.3 V
10. Inverter 2- 2 A 718.56 V 710.4 V
11. Inverter 2- 2 B 734.99 V 727 V
12. Inverter 2- 2 C 718.32 V 710.3 V
13. Inverter 3- 1 A 738.62 V 729 V
14. Inverter 3- 1 B 741.79 V 733.4 V
15. Inverter 3- 1 C 723.16 V 715.3 V
16. Inverter 3- 2 A 721.81 V 712.2 V
17. Inverter 3- 2 B 732.13 V 723.1 V
18. Inverter 3- 2 C 719.32 V 710.3 V
19. Inverter 4- 1 A 695.38 V 690.2 V
20. Inverter 4- 1 B 694.22 V 689.3 V
21. Inverter 4- 1 C 695.21 V 690.2 V
22. Inverter 4- 2 A 696.44 V 691.2 V
23. Inverter 4- 2 B 695.47 V 690.4 V
24. Inverter 4- 2 C 720.09 V 714.6 V
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Connecting the PV system to the Grid
The four inverters were connected to the Grid through a 95mm AC cable.
Configuration of the inverters
The independent mode was selected for the inverter, so that each the MPPT will operate
independently
The Italian grid standards were selected( equivalent to WAPDA Standards)
The language selected was English
The time was set according to the Pakistan standard time
Operation Start
All the four inverters were configured in the presence of ABB representative and were synced with
WAPDA. The operation was ok and all the inverters were working properly.
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Commissioning Details:
Commissioning of this grid-tied solar power plant was carried out at 2:10 pm on 24 August 24, 2015.
With breaks of ten minutes duration all inverters were turned on one by one. Results were recorded which
at 2:00 pm were:
Inverter 1: 23.5 KWh
Inverter 2: 23.8 KWh
Inverter 3: 23.3 KWh
Inverter 4: 22.9 KWh
Communication and Monitoring:
Inverter communication is made possible with 485 networking protocol. For monitoring Aurora
Communicator software is used. An all inverts data displayed on desktop computer. An updating Email is
enabled for daily production monitoring. A Fault Email is also enabled so that in future if any fault may
occur then addressed that faults accordingly.
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Checks & Protections:
PANEL:
Open Circuit Voltage Check: All 504 Panels were found with 32 Volts and above (in peak
hours).
Short Circuit Current Check: All 504 Panels produced 7 A and above (in peak hours)
All panel connections are checked and isolated and protected and proper grounding is made by earthing
wire.
INVRERTER:
Inverter output and all other parameters as per technical datasheet and check accordingly. All inverters
connection checked and all inverters a properly earthed with earthing wire.
DB Panel:
DB panel Isolation and connection checked. All cable connections are correct, isolated and protected. DB
panel is properly earth with LT Room earth wire.
Communication:
All communication setup is already checked. All inverters monitored on desktop computer and their
parameters.
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Single Line Diagram of 128Kwp Solar Grid Tied PV system:
Special Thanks:
Premier Energy and its Project Team are thankful to Mill Management to support us in
energy stage of project which is no doubt looks very professional working.
Remarks:
Premier Energy recommends regular cleaning of PV Panels will be maintained.
Signed By:
____________________ ____________________
Mahmood Ahmed Fazal Yasin
Manager Technical Operations Manager Electrical
Premier Energy (Pvt.) Ltd Masood Spinning Mill (MSM)
(Pvt) Ltd