Professional Documents
Culture Documents
Session 2 ‐ Execution and
Commissioning
Javier Relancio & Luis Recuero
Generalia Group
September 16th 2010
http://www.leonardo-energy.org/training-pv-systems-design-
construction-operation-and-maintenance
PHOTOVOLTAIC SYSTEM
Design, Execution, Operation & Maintenance
EXECUTION AND COMMISSIONING
Javier Relancio. Generalia Group. 16/09/2010
www.generalia.es
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INDEX
Mechanical works
Electrical works
Environmental issues
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INDEX
Mechanical works
Electrical works
Environmental issues
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Civil Works: Infrastructure preparation
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.
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Terrain leveling
Source: QHOELET
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Internal roads & paths
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Internal roads & paths
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.
Natural terrain
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Trenches
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Trenches
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INDEX
Mechanical works
Electrical works
Environmental issues
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Mechanical works
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
No wind action Important wind action
Lower cost (Both for structure & Higher cost (Both for structure &
mounting) mounting)
Photo: Krannich
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Mechanical works
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
Source: Conectavol
They can’t 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)
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Roof anchorage
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PV Roofs
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.
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
Element Weight
Structure 2KG
Crystalline panels 15KG
Thin film laminated panel 6KG
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
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INDEX
Mechanical works
Electrical works
Environmental issues
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Electrical works
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Electrical works
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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Electrical works
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.
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Electrical cabinets
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Earthing system
PV panel frameworks
Structure
Metal cable tray
Metal elements in electrical cabinets
PV inverters
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INDEX
Mechanical works
Electrical works
Environmental issues
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Our solar facility and the environment
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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Environmental aspects & impacts
Residue: Any substance or object from which his holder detaches or has the obligation
to become detached following the European rules & standards
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Environmental aspects & impacts
We must take into account the environmental management of our solar facility
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
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Example: Environmental management during
the project execution
Atmospheric contaminations
Electric energy consumption N
Visual Impacts
PV installations (and Fuel consumption N Atmospheric pollution
Suntrackers, in case Powder generation N Atmospheric pollution
of being used) Residues generation N Space in the dumpsite
Atmospheric pollution
Fire E
Impact on the fauna & flora.
N: Normal; E: Extraordinary
2. Emergency classification
Significant
Aspect P S A
YES=Y; NO=N
Fire 2 4 8 Y
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Example: Environmental management during
the project execution
SIGNIFICANT
ASPECTS F S C A
YES/ NO
Electrical energy consumption 5 2 2 20 YES
Dangerous residues generation 3 2 2 12 NO
Urban residues generation 4 1 2 12 NO
Noise generation 3 1 1 6 NO
Fuel consumption 3 2 2 12 NO
Powder generation 3 1 1 6 NO
Paper consumption 5 1 2 15 YES
Packages 4 1 2 12 NO
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Example: Environmental management during
the project execution
4. Emergency plan
EVENT/ EMERGENCY: FIRE
Preventive measures Adaptation to the electrical and construction regulations. Fire‐extinguishers.
• The work manager is the person in charge of the extinction of fire.
• In case of non‐controllable emergency, the work manager will take charge of
warning the external emergency services.
Actuation plan
• The work responsible is the person in charge of giving the alarm and
controlling the evacuation of the whole staff. He must check that the
evacuation has been completed
Practice Fire
The response time will be measured for the following aspects:
• The fire warning.
Practice description
• Staff evacuation.
• The checking that the evacuation has been completed.
Frequency Yearly
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Example: Environmental management during
the project execution
Urban residues Dangerous residues
Paper Toner with metallic components
Plastic Batteries
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Mechanical works
Electrical works
Environmental issues
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Quality: Critical aspects
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 early
breakdowns
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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Quality: Critical aspects
Work
Manager
1.Checking that the items indicated in 1.Checking that the items that have
the delivery notes corresponds with arrived correspond to the items of
the ordered ones the delivery note
2. Checking any lacking item in the 2.Visual checking
order and claiming for it 3.Checking of electrical and
3. Checking the payments mechanical characteristics
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Quality: Critical aspects
Work Manager
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Panel inspections
Samples
selection
VISUAL ELECTRICAL THERMAL
Packages
OF Panel arrays Panels
Panels
The electrical
• Frame defects characteristics differ from Cell defects
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 elements
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Thermography
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INDEX
Mechanical works
Electrical works
Environmental issues
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Labor risks evaluation plan
1. Introduction
Knowledge of the particularities
of the company activities
Risk analysis for each activity
Actions depending on the risks
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Labor risks evaluation plan
2. Activitie characteristics
Small facilities: From 2‐3 KW to 100KW
Larger facilities: >100 KW Larger facilities: >100 KW
(Or even more)
Sharing the work with the industry
Larger number of workers Larger number of workers
where our plant is located
Electrical cabling and inverter Usage of cranes to fix the panel structure
Possibility of using cranes
commissioning to the Suntrackers
Electrical cabling and inverter Electrical cabling and inverter
commissioning commissioning
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Labor risks evaluation plan
3. Activity risks
Risk from the industry where the
Electrocution risk Electrocution risk
plant is located
Accident due to collision with the suntracker
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Labor risks evaluation plan
4. Activitie summary
To analyze the photovoltaic activities, to know and to evaluate the risks of every job
inside every activity.
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INDEX
Mechanical works
Electrical works
Environmental issues
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Project commissioning
Technical documentation
Project design
Execution
Commissioning checklist
Plant production checking
Project modification Generator production checking
Done inspections Inverter production checking
Element identification
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Plant production checking
As the aim that we pretend is to maximize the productive capacity of the photovoltaic solar
plant, we need to check, from time to time, a test of the plant productive capacity (i.e. every
three years)
We will evaluate:
The power, in alternating current at the plant output (meter)
Global and direct irradiance in a calibrated cell (from a similar technology to the one used
for the generator and parallel with it)
Cell temperature: sticking a thermal sensor to the calibrated cell
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Plant production checking
Irradiance
A meteorological station
where the information of
Temperature and irradiance
will be registered
TEMP. PANEL FV
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Plant production checking
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
Condition: The minimal period of irradiance over 600W/m2 must be at least 12 hours
If the legislation allows it in the future, the modernization or extension of the plant for
repowering might be recommended
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Testing of PV Generator electrical
characteristics
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Testing of the inverter electrical characteristics
Source: SMA
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End of Session 2
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construction-operation-and-maintenance
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