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CONTRACTOR
GES CONTRACT NO: D-G502-1316
WORK ORDER NO:CMIT-110-ELE-15.03-0010
SPECIFICATION
FOR
SOLAR POWER UNIT
B ISSUED FOR APPROVAL 30.06.2015 SUN FEIXIAO SHI FENGYUAN LI CHUN MA KUN
A ISSUED FOR REVIEW 10.04.2015 SUN FEIXIAO SHI FENGYUAN LI CHUN MA KUN
CONTENT
1.0 SCOPE
This Specification covers the minimum requirements of design, manufacturing, testing
and supply of 24V DC Solar Power Unit including all items of equipment and materials
necessary to complete the assembly and the information, documents and data required
to be supplied by the vendor.
It is important that any shadowing be reduced as much as is practical. Note that even a
small shadow on the array can significantly limit its performance.
Issues of performance degradation due to temperature rise and the need for good
ventilation were described before. Care should be taken to keep modules as cool as
practicable.
Volt drop can be particularly significant in systems with low output voltage and high
output current. Under maximum load conditions the voltage drop from the most remote
COMPANY
CONTRACTOR
GES CONTRACT NO: D-G502-1316
WORK ORDER NO:CMIT-110-ELE-15.03-0010
module in the array to the terminals of the application circuit should not exceed 3 % of
the PV array voltage at its maximum power point.
Pollution of the surface of PV modules caused by dust, dirt, bird droppings, snow, etc.,
can
significantly reduce the output of the array. Arrangements should be made to clean the
modules regularly in situations where significant pollution may be a problem.
The solar arrays panel shall consist of a toughened glass having a high light absorption
coefficient and shall be completely encapsulated.
Equal sharing of loads from each solar array module either in series connection or
parallel-series combination shall be achieved and provided.
All equipment, including the solar array, control equipment, batteries and associated
components, shall be suitable for installation in the area in which it is to be installed.
Unless specified otherwise, all equipment should be located in a safe, non hazardous
area.
The power output from the solar power unit shall be sufficient to supply the loads listed
in data sheet.
The supplier shall submit the proposed design and calculations for the owner’s approval
as per the content of this document. The design shall include all interconnections and
interfaces.
PV modules ratings are stated at standard test conditions (25 °C).Under normal
operating conditions, cell temperatures rise significantly above ambient. A typical
temperature rise of 25 °C is common with respect to the ambient temperature for
crystalline silicon PV modules operating at the maximum power point under 1000 W/m2
solar irradiance and with adequate ventilation. The temperature rise can be
considerably higher when irradiance levels are greater than 1000 W/m2 and when
modules have poor ventilation therefore attention shall be paid to following points:
COMPANY
CONTRACTOR
GES CONTRACT NO: D-G502-1316
WORK ORDER NO:CMIT-110-ELE-15.03-0010
Bank
The following data shall be provided for the storage batteries:
Load pattern.
Battery chargers factor (efficiency).
Acceptable maxim um Daily Depth of Discharge (DDOD)
Calculated maximum DDOD
Calculated average DDOD.
Acceptable minimum state of charge.
Calculated minimum battery back-up time.
Calculated average battery back up time.
The maximum time taken to fully charge the battery at the end of the back-up time.
The maximum, average, and minimum terminal voltage supplied to the equipment
during day and night.
System losses and de-rating factors due to the following shall be stated:
Charging efficiency of the batteries.
Ageing
Dust deposit
Environmental conditions (temperature, wind, sandstorms, hail)
Insolation variation due to normal year to year statistical changes
Current consumed by control equipment、metering and alarm system
Losses in control equipment, wiring, fuses, diodes and circuit breakers
The Supplier shall submit evidence of satisfying the basic requirements by means of a
design and system simulation taking into account all parameters mentioned above.
From the minimum state of charge level mentioned in the foregoing paragraph, the
system shall also under conditions of minimum daily average insolation recharge the
battery to full charge level, while at the same time supplying rated power output to the
load.
COMPANY
CONTRACTOR
GES CONTRACT NO: D-G502-1316
WORK ORDER NO:CMIT-110-ELE-15.03-0010
The solar module rating shall be such that at any moment the battery charge factor shall
be 1.2 minimum, and the Daily Depth of Discharge (DDOD) shall not be more than
15%of full capacity depending on type of battery and ambient temperature of the battery
location.
If the solar modules are installed at a significant distance from the load and/or battery,
attention shall be given to the selection of the output voltage and the cross-sectional
area of the cabling to avoid unacceptable losses.
Site and panel temperature must be taken into account for the performance of the solar
modules.
Electrical connections shall be made to a junction in which two by pass diodes shall be
incorporated to prevent PV modules from being reverse biased and consequent hot
spots.
The junction box shall contain both positive (+) and negative (-) terminals and panel
interconnection cables wiring. PV array and PV string combiner boxes exposed to the
environment shall be at least IP 55 and shall be UV resistant.
Each diode shall have a minimum direct current value of three times the short circuit
current of the array on which it is installed.
If external bypass diodes are used, and they are not embedded in the PV module
encapsulation or not part of factory mounted junction boxes, they shall comply with the
following requirements:
– have a voltage rating at least 2×VOC of the protected module;
– have a current rating of at least 3×ISC of the protected module;
– be installed according to module manufacturer’s recommendations;
– be installed so no live parts are exposed;
– be protected from degradation due to environmental factors
– be installed so no live parts are exposed;
– be protected from degradation due to environmental factors
The solar modules shall be mounted on a frame suitable for installation at site.
The support frame shall be constructed from corrosion resistant, heavy extruded
aluminium alloy with 3 mm minimum thickness suitable for the climatic conditions and
the whole installation capable of withstanding the wind and storm conditions.
This frame shall be designed for tilting to the optimum angle for absorption of energy
and also for creating a self-cleaning washing of the module surface when it rains.
Design shall allow bolted field assembly and array angle adjustment in increments of 5
degrees without special tools or drilling. Each tilt increment shall be permanently labeled
for identification of tilt angle.
Array support structure shall be constructed to allow easy and comfortable access to
normal maintenance points such as the batteries, charging regulator and output control
centre Mounting heights and locations shall be ergonomically designed wherever
possible. Mounting height of longer edge of photovoltaic panels shall be not less than
0.8 m above ground at a 35 degree tilt angle to avoid dust concentrations.
The frame shall be supplied with holes or slides for mechanical attachment. Where
thermal stresses due to expansion coefficient differentials between aluminum
photovoltaic panel frames and array support structure are anticipated, mounting
allowances for movement shall be included. Self-locking hardware and nylon washers
shall be used where specific torque is needed to allow for thermal expansion
Vendor shall provide construction dimensions in a clear, easy-to-read format explaining
foundation requirements and recommendations for anchoring the array, support
structure, and batteries
8.0 BATTERY
Batteries shall be the deep-cycle, long-life maintenance free, and sealed type design,
proven for solar power system use. The effects of site temperatures on available
capacity and lifetime expectancy shall be taken into account in the selection of the
battery type.
The expected service life of shall be stated for the service conditions stated herein and
shall have the following features:
They shall not degrade more than 20 percent of full capacity over their service life.
Battery capacity shall not be allowed to fall below 20 percent of full capacity during
operation.
The self discharge rate shall be<2%per month at 25 ℃.
Cooling of the batteries shall be by natural air flow and good design practice only,
forced cooling shall not be used.
The batteries shall be arranged to facilitate access for maintenance purposes. Inter cell
connectors shall be provided. The use of parallel arrangements should be avoided.
Solar charge controller should be able to operate at various system voltages listed in
data sheet.
The charge regulator controller shall incorporate a means to sense the storage battery
bank temperature and prevent accidental overcharging. The charge regulator controller
shall effectively control the input charging voltage to the storage battery bank to prevent
overcharging or uneven charging and shall have a 24V-DC input to allow battery
charging by portable power generator in case of emergency. The charge regulator
controller enclosure shall be IP55 for outdoor.
Each solar power unit shall have a power distribution unit (PDU) .The PDU shall be of
modular design for ease of component replacement and maintenance and shall ensure
proper charging and discharging of the batteries through the following functions:
Dual voltage regulation to cater for boost and float operation.
Overcharge protection of the batteries by switching off the solar array from the
system if the battery is already fully charged.
Battery protection by switching off the load from the system if the voltage drops
below voltage limits and alarm contact for warning of low battery voltage.
Temperature compensation maximum charge voltage.
Prevention of overnight discharge of the batteries through the solar array.
Protection against over voltage from the solar module output.
Note: To protect the DC system against overvoltage surge, surge protective devices shall be
fitted between active conductors and between active conductors and earth at the inverter end of
the DC cabling and at the array.
Protection against overload and short circuit conditions in the connected load.
Note: Overcurrent protection devices required for the protection of PV modules and/or wiring
shall be selected to reliably and consistently operate within 2 h when an Overcurrent of 135 %
of the nominal device current rating is applied. Other requirements of IEC TS 62548 as stated in
clauses 6.3 to 6.6 shall be complied.
Protection against Earth fault detection to eliminate the risk of fire.
Note: It shall not interrupt the connection of exposed metal parts to earth Fault clearing
time limits shall follow table 4 of TS 62548. Following fault clearance an alarm (Visual and
Audial) shall be triggered to warn operator.
The PDU shall include a voltmeter and ammeter and LED Indications for all battery
alarms etc.
As a minimum the following shall be provided to indicate system status:
Battery voltage below minimum voltage.
Battery voltage above maximum voltage.
Voltage free contacts for remote indication of battery low voltage.
The PDU shall incorporate a SPDT (Single Pole Double Throw) contactor which gets
actuated on battery low voltage. The contactor rating shall allow for the inductive load
during switching. Terminals shall be provided on the solar panel control module for
COMPANY
CONTRACTOR
GES CONTRACT NO: D-G502-1316
WORK ORDER NO:CMIT-110-ELE-15.03-0010
remote monitor, alarm and signaling. Local programmable module with display panel
shall be provided. Failure of the PDU shall not result in catastrophic failure of the whole
system.
The input voltage rating of this distribution board equipment shall be 24V-DC, 2-wire, +/-
2% tolerance, with main protection (MCCB) and branch circuit protections (MCBs) and
with minimum 10kA short circuit current bus bracing. Earthing busbar shall also be
provided inside each of the dc-distribution board. There shall be suitable number of
spare (i.e. 25 % spares) circuit breakers of correct rating to be provided.
Harmonic content shall be limited to maximum 2% and RF interference shall not affect
proper operation of the system.
The interconnection between the solar array and the PDU shall be made by means of a
DC circuit breaker to facilitate the electrical isolation of the solar modules from the
system for repair or replacement.
The interconnection between the battery bank and the PDU shall also be made by
means of a DC circuit breaker to facilitate the electrical isolation of the battery from the
system for inspection and maintenance purposes.
Circuit breakers used for overcurrent protection in PV arrays or at battery Bank shall
be certified to either IEC 60898-2 or IEC 60947-2 and
not be polarity sensitive;
be rated to interrupt full load and prospective fault currents from the PV array and
any other connected power sources such as batteries, generators and the grid if
present;
be rated for overcurrent as specified in this specification
String cables be flexible (class 5 of IEC 60228) to allow for thermal/wind movement of
arrays/modules
Different types of circuits and cables thereon shall be clearly identified and segregated
All cables shall be 600/1000 V grade, copper conductor, PVC insulated, PVC sheathed,
steel wire armored with PVC outer sheath (PVC/PVC/SWA/PVC)
Cable terminations on wiring shall be made with crimped lugs connectors appropriately
sized for the conductor. Spade-type terminations are not acceptable. Large current
carrying conductors over 70 mm² may terminate at tinned or silver coated crimped type
lugs located in the respective enclosures. Split-bolt connectors are not acceptable
Cable ties shall not be used as a primary means of support unless they have a lifetime
greater than or equal to the life of the system or the scheduled maintenance period.
12.0 EARTHING
Earthing / bonding of exposed conductive parts of a PV array shall be performed to
avoid uneven potentials across an installation including against lightning overvoltage.
When the PV array is earthed as described in 7.4.2.1 d) the connection to earth shall be
made at a single point and this point shall be connected to the main earthing terminal of
the electrical installation.
High impedance shall exist between all live conductors and the equipment earthing
conductors
The minimum current carrying capacity of the main earth conductor shall be no less
than (PV array maximum voltage)/R. Where R is the resistance value used in series
with the functional earth connection for a system which has a functional earth
connection via a series resistor.
The conductor used to earth exposed metallic frames of the PV array shall have a
minimum size of 6 mm2 copper or equivalent which may need to be larger due to
lightning system requirements.
PV array bonding conductors shall be run as close to the positive and negative PV array
and or sub-array conductors as possible to reduce induced voltages due to lightning.
With respect to material and type, insulation, identification, installation and connections,
earthing conductors shall comply with the provisions for earthing conductors specified in
national wiring standards, or in absence of such standards, with the provisions set out in
IEC 60364-5-54.
COMPANY
CONTRACTOR
GES CONTRACT NO: D-G502-1316
WORK ORDER NO:CMIT-110-ELE-15.03-0010
13.0 TESTS
The complete solar system complete with all interconnecting cables shall be tested at
the Supplier’s works in accordance with applicable codes and manufacturer’s standard
testing procedures. The Supplier shall submit copies of the subject test certificates to
the Owner Testing shall include the following:
Visual inspection,
Insulation test on all cables.
Functional testing of the complete system.
Load testing of complete installation.
Battery discharge test.
Measurement of typical values of solar module short circuit current and open circuit
voltage.
16.0 WARRANTY
The Supplier shall guarantee that the equipment furnished is free from fault in design,
workmanship, is of adequate size and capacity, and of proper material to satisfactorily
fulfil the operating conditions specified. Should any defect in design, material,
workmanship or operating characteristics develop during the first year of operation, the
Supplier shall make all necessary alterations, repairs, and replacements of defective
equipment/components. at his own cost including transportation, installation and testing.
an ocean environment. Care must be taken to protect the skids from external attack by
the elements and from the impact of moisture and humidity on the equipment.
It is likely that a certain amount of disassembly will be required for shipment including
some of the mechanical components and some instrumentation. The vendor shall
provide very specific detailed instructions for reassembling the components and must
assume that reassemble of the components will be done by unskilled. If in the vendors’
opinion the reassembling cannot be done by unskilled labor then the vendor must
include in its proposal for the services of its own skilled personnel to go to the site and
supervise or undertake the reassembling and verification that the equipment is suitable
for operation.
Adoption of suitable packing methods and materials is at the sole discretion of the
Vendor, and should any loss, damage and/or deterioration be caused due to improper
packing, the consequences shall be the responsibility of the Vendor.
The maximum dimensions of any package should not exceed 2.4 meters in width, 3.3
meters in height, and 12 meters in length (the indicated Width and Height can be
increased to 3.0 m and 5.0 m with special permission by the government), and total
weight should not exceed 30 tones. Packages larger or heavier than this will require
approval of the Purchaser.