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German Pakistan Financial Cooperation
Development of Hydropower & Renewable Energy (HRE)Project Khyber-Pakhtunkhwa
(Phase-I)
TECHNICAL GUIDELINES & REPORTS
VOLUME 4: DESIGN OF PV COMMUNITY SYSTEMS
JULY 2013
DRAFT
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Table of Content
1 Basic Features 21.1 Cluster __________________________________________________________ 21.2 Demand _________________________________________________________ 21.3 Solar Radiation ___________________________________________________ 21.4 Sizing ___________________________________________________________ 31.5 Supply Voltage ___________________________________________________ 4
2 System Lay-Out 52.1 Modules _________________________________________________________ 52.2 Batteries _________________________________________________________ 52.3 Wiring __________________________________________________________ 52.4 House installations ________________________________________________ 5
3 ANNEXES 7
INTEGRATION Environment & Energy Ltd.Bahnhofstr. 991322 Graefenberg / Germanywww.integration.org
Ulrich Frings
July 2013
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1 Basic Features
The solar street/home lighting systems (SSLS) are foreseen to supply clusters of houses withbasic electricity for lighting and cooling (fan) purposes. The supply of single houses is notforeseen.
1.1 Cluster
In order to limit design works the supply systems have been grouped into 4 clusters containing 5,10, 15 and 20 houses. For each group standard designs for all equipment are made available tothe POs. Additional design works per site is thus limited to adjustment of foundation, fencing plan
and wiring.
1.2 Demand
Considered appliances are compiled in Annex 1 and summarized in Table 1. A typical daily loadschedule for winter and summer is presented in Figure 1 for a 5-house cluster. Power for lightingis required during early morning and evening. Main consumer is the fan during summer.
Table 1: Recommended Appliances per houseItem Amount Total Watt Remarks
Room lighting 2 22 1 bulb of 11 W
Fan 1 75
Street lighting 0.2 4 1 per 5 householdsMobile charging 0.2 1 1 per 5 households
Total 104Source:PPAF
Figure 1: Load Schedules Cluster 1: 5 householdsDaily load Summer Daily load Winter
Source: Annex 1.1
1.3 Solar Radiation
Monthly solar radiation for North Pakistan is shown in Figure 3. As expected, radiation is at peakduring summer and at minimum during winter months. An exceptional case is in August wheredue to the monsoon rains and the accompanying higher cloudiness the radiation values arecomparable lower.
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Figure 2: Monthly Solar Radiation
Source: HOMER Software
1.4 Sizing
The systems shall provide the demanded basic electricity throughout the year. As mentionedabove critical period will be the month of August where comparable lower radiation meets theannual peak demand. A typical situation in beginning of August is presented in Figure 3.
Figure 3: Capacity shortage in August
Source: Own calculations; HOMER Simulation Software;
Shortage starts at 2nd
of August evening after batteries are discharged to its maximum 70%.During 3rdof August PV power is just enough to supply the daily demand; battery recharge is
Battery state of charge (%)
Inverter Output (load)
PV Power (Generator)
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marginal. During 4
th
of August batteries are partly recharge (part of which is used during theevening and night. Recharge continues during 5thand 6thof August.
However, a zero capacity shortage would require extraordinary large systems in terms ofmodules and batteries which would considerable increase costs which seems not economicalfeasible, the more that a high percentage of installed capacity would remain unused for most ofthe year.
The system sizing is therefore based on an allowable power shortage factor of max. 1% and apeak reserve of 5.
In order to minimize negative impacts on electricity supply during these days, the POS shall
introduce respective measures to the community. Such measures might include: Reduction of load during these days (e.g. street lighting, mobile charging)
Load shedding
Reduction of fan hours.
1.5 Supply Voltage
The supply voltage depends mainly on the distance from generator to consumer and the relatedvoltage losses along the line. In addition, appliances are available at 230 V AC, 50HZ or for 12 VDC voltage, whereby the latter are more expensive and not always available compared to the ACdriven appliances).
Voltage drops as function of diameter of cable and cable length are compiled in Annex 2.Maximum voltage drop along the distribution line should not exceed 10-25%. As can be takenfrom Annex 2 even for the 5 households cluster a distance of 40 m would require already 35mm cable. The same cross section would reach only about 10 m in case of the 20 householdscluster. Additional voltage losses are to expected at loosening cable connections and joints overthe years.
Consequently, a 12 V DC supply is only feasible for single house supplies or in extraordinarycases where houses are located very close together. It is therefore recommended to base thesystems on 230 V AC voltage which ensures:
- Sufficient voltage level within the houses to run the appliances- metering with common power meters (if required)- operation of common appliances available at lower cost- Reduced cost for wiring due to lower cable sizes- More buffer against weak and ageing installations with accompanying growing resistivity
and related growing voltage losses- Optimization of generator location (distances of up to 100 m from generator to house are
possible).
The operation at 220 V AC requires a DC/AC inverter which parallel acts as charge controller forthe batteries. The minimum design requirements are compiled in Table 2.
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Table 2: Design AspectsItem Minimum lifetime Others
Battery 7-8 years Maintenance free, sealed gel solar batteries to minimizerequirements on battery storage and to minimize risks ofhazards and environmental pollution
Module 20 years Crystalline systems
bulbs 10 Years (20,000 hrs) Energy saving bulbs or LEDS
Street light 10 years LED (15,000 hrs)
Supply voltage 220 V ACSource: own compilations; Annex 3
2 System Lay-OutThe sub-project comprises of a centralized PV generator including batteries, charge controller andinverter, the distribution lines to the houses, and the supply of the street lights. Householdappliances are to be purchased by the customers themselves1.
With respect to in-house appliances basic technical features should be given to the customersand communities in order to ensure that power demand is kept in the envisaged limits2.
2.1 Modules
Modules will be installed on iron supports which could be local made. The supports are fixed in R/fconcrete strip foundations. A standard lay-out is shown in Annex 3.1. Close to the module area, abattery room including all necessary control devices is erected. The entire area should beprotected (fences, walls) in such a way that the modules are prevented against damaging.
2.2 Batteries
Batteries are placed in a battery room. The room should be insulated in such a way that theminimum and maximum temperatures of the batteries are always (-20C +45C) and optimaltemperatures (+15C - +35C) are met during most of the time.
2.3 Wiring
Wiring should be done by using XLPE 2 core, double insulated (outer and inner shield) Al cable of0.6 to 1kV nominal voltage. The diameter depends on the distances from the generator to thehouses and needs to be adjusted to the local conditions. Fixing of cables could be done at wallsby using appropriate tools and at 5-7m steel or wooden poles.
2.4 House installations
House installation is not part of the project. However, prior to connection the house installationshould be inspected and certified by the PO in order to ensure minimum safety and qualitystandards. With respect to the comparable low demand, installation of meters is not essential.However, MCBS and RCBOs should be installed in each house for safety purposes.
1Technical specifications and lists of recommended equipment should be provided by the POS to the communities and customers
2PV systems are very sensitive against overload. Thus, the community should be able and willing to control installed appliances and
power consumption
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System sizing
Simulation of power generation and consumption have been conducted for each cluster by usingHOMER Software. The results are compiled in Annex 4 and summarized in Table 3.
The simulation is based on the given summer and winter load schedules (Figure 1 and 2), thesolar radiation figures (Figure 3) and the following parameter:
Operating reserve 5%
Permissible capacity shortage:
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3 ANNEXES
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Annex 1: Appliances
Annex 1.1: Cluster 1 5 households
NumberofTargetHouses 5 Nos
S.No Description Nos Appliance
s
1 Avergagehousesize
(rooms) 2 10
2 AirCooling
Fan 1 5
3 StreetLighting 1 1
4 MobilChargingfacility 1 1
S.No Appliance(DCPower) Units Wattage
(Watts)
Total
Wattage
Daily
Operation
Hours
Total
Energy
(Wh)
1 Room
Lighting
(ES) 10 11 110 6 660
3 StreetLights(ES) 1 20 20 10 200
4 AirCoolingFan(AC) 5 75 375 10 3.750
5 MobileCharger 1 5 5 3 15
ActualDailyEnergyDemand 0 0 510 4.625
6 1.388
6.013
TheFudgeFactor@30%(SystemLossesforDCpowerPVsystem)
Clusterof5houses
Rational
1lightperroom
A.Data
1fan
Per
house
1streetlightperclusterof5
houses
InBuiltMobileCharger(s)
B EnergyDemand
NETDailyEnergyDemand(Wh)
Daily load summer Daily load winter
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Annex 1.2: Cluster 2 10 households
NumberofTargetHouses 10 Nos
S.No Description Nos Appliance
s
1 Avergagehousesize
(rooms) 2 20
2 AirCoolingFan 1 10
3 OutsideLighting 1 2
4 MobilChargingfacility 2 2
S.No Appliance(DCPower) Units Wattage
(Watts)
Total
Wattage
Daily
Operation
Hours
Total
Energy
(Wh)
1 RoomLighting(ES) 20 11 220 6 1.320
3 StreetLights
(ES) 2 20 40 10 400
4 AirCoolingFan(AC) 10 75 750 10 7.500
5 MobileCharger 2 5 10 3 30
ActualDailyEnergyDemand 0 0 1020 9.250
6 2.775
12.025
InBuiltMobileCharger(s)
Clusterof5houses
A.Data
Rational
1lightperroom
1fanPerhouse
1street
light
per
cluster
of
5
houses
B EnergyDemand
TheFudgeFactor@30%(SystemLossesforDCpowerPVsystem)
NETDailyEnergyDemand(Wh)
Daily load summer Daily load winter
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Annex 1.3: Cluster 3:- 15 households
NumberofTargetHouses 15 Nos
S.No Description Nos Appliance
s
1 Avergagehousesize
(rooms) 2 30
2 AirCoolingFan 1 15
3 OutsideLighting 1 3
4 MobilChargingfacility 2 2
S.No Appliance(DCPower) Units Wattage
(Watts)
Total
Wattage
Daily
Operation
Hours
Total
Energy
(Wh)
1 RoomLighting(ES) 30 11 330 6 1.980
3 Stre etLights(ES) 3 20 60 10 600
4 AirCoolingFan(AC) 15 75 1125 10 11.250
5 MobileCharger 2 5 10 3 30
ActualDailyEnergyDemand 0 0 1525 13.860
6 4.158
18.018
InBuiltMobileCharger(s)
Clusterof5houses
A.Data
Rational
1lightperroom
1fanPerhouse
1streetlightperclusterof5
houses
B EnergyDemand
TheFudgeFactor@30%(SystemLossesforDCpowerPVsystem)
NETDailyEnergyDemand(Wh)
Daily load summer Daily load winter
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Annex 1.4: Cluster 4 20 households
NumberofTargetHouses 20 Nos
S.No Description Nos Appliance
s
1 Avergagehousesize
(rooms) 2 40
2 AirCoolingFan 1 20
3 OutsideLighting 1 4
4 MobilChargingfacility 3 3
S.No Appliance(DCPower) Units Wattage
(Watts)
Total
Wattage
Daily
Operation
Hours
Total
Energy
(Wh)
1 RoomLighting(ES) 40 11 440 6 2.640
3 StreetLights(ES) 4 20 80 10 800
4 AirCoolingFan(AC) 20 75 1500 10 15.000
5 MobileCharger 3 5 15 3 45
ActualDailyEnergyDemand 0 0 2035 18.485
6 5.546
24.031
InBuiltMobileCharger(s)
Clusterof5houses
A.Data
Rational
1lightperroom
1fanPerhouse
1streetlightperclusterof5
houses
B EnergyDemand
TheFudgeFactor@30%(SystemLossesforACpowerPVsystem)
NETDailyEnergyDemand(Wh)
Daily load summer Daily load winter
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Annex 2: Voltage Drops in Cables
Annex 2.1: Cluster 1 5 households
MaxLoad 500 W
SystemVoltage 12 V
SystemCurrent: 42 A
cable(mm): 0,75 1 1,5 2,5 4 6 10 16 20 25 35
distanceto
house(m)
1 17 13 9 5 3 2 1 1 1 1 05 87 66 44 26 16 11 7 4 3 3 2
10 175 131 87 52 33 22 13 8 7 5 4
15 262 197 131 79 49 33 20 12 10 8 6
20 349 262 175 105 66 44 26 16 13 10 7
25 437 328 218 131 82 55 33 20 16 13 9
30 524 393 262 157 98 66 39 25 20 16 11
35 611 459 306 183 115 76 46 29 23 18 13
40 699 524 349 210 131 87 52 33 26 21 15
45 786 590 393 236 147 98 59 37 29 24 17
50 874 655 437 262 164 109 66 41 33 26 19
CalculationoflossesinAlcable
Cluster1:5households
Deltau(%)
0
5
10
15
20
25
30
35
40
45
50
1 5 10 15 20 25 30 35 40 45 50
Deltau(%)
Voltagedropalongcable
0,75 1,0mm 1,5mm 2,5mm 4 6 10 16 20 25 35
distanceinm
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Annex 2.2: Cluster 2 10 households
MaxLoad 1020 W
SystemVoltage 12 V
SystemCurrent: 85 A
cable(mm):
0,75 1 1,5 2,5 4 6 10 16 20 25 35
distanceto
house(m)
1 36 27 18 11 7 4 3 2 1 1 1
5 178 134 89 53 33 22 13 8 7 5 4
10 356 267 178 107 67 45 27 17 13 11 8
15 535 401 267 160 100 67 40 25 20 16 11
20 713 535 356 214 134 89 53 33 27 21 15
25 891 668 445 267 167 111 67 42 33 27 19
30 1069 802 535 321 200 134 80 50 40 32 23
35 1247 936 624 374 234 156 94 58 47 37 27
40 1426 1069 713 428 267 178 107 67 53 43 31
45 1604 1203 802 481 301 200 120 75 60 48 34
50 1782 1336 891 535 334 223 134 84 67 53 38
CalculationoflossesinAlcable
Cluster2:10households
Deltau(%)
0
5
10
15
20
25
30
35
40
1 5 10 15 20 25 30 35
Deltau(%)
Voltagedropalongcable
1,5mm 2,5mm 4 6 10 16 20 25 35
distanceinm
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Annex 2.3: Cluster 3 15 households
MaxLoad 1525 W
SystemVoltage 12 V
SystemCurrent: 127 A
cable(mm): 0,75 1 1,5 2,5 4 6 10 16 20 25 35
distanceto
house(m)
1 53 40 27 16 10 7 4 2 2 2 1
5 266 200 133 80 50 33 20 12 10 8 6
10 533 400 266 160 100 67 40 25 20 16 11
15 799 599 400 240 150 100 60 37 30 24 17
20 1066 799 533 320 200 133 80 50 40 32 23
25 1332 999 666 400 250 167 100 62 50 40 29
30 1599 1199 799 480 300 200 120 75 60 48 34
35 1865 1399 932 559 350 233 140 87 70 56 40
40 2131 1599 1066 639 400 266 160 100 80 64 46
45 2398 1798 1199 719 450 300 180 112 90 72 51
50 2664 1998 1332 799 500 333 200 125 100 80 57
CalculationoflossesinAlcable
Cluster3:15households
Deltau(%)
0
5
10
15
20
25
30
35
40
45
1 5 10 15 20 25
Deltau(%)
Voltagedropalongcable
1,5mm 2,5mm 4 6 10 16 20 25 35
distanceinm
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Annex 2.4: Cluster 4 20 households
MaxLoad 2035 W
SystemVoltage 12 V
SystemCurrent: 170 A
cable(mm): 0,75 1 1,5 2,5 4 6 10 16 20 25 35
distanceto
house(m)
1 71 53 36 21 13 9 5 3 3 2 25 356 267 178 107 67 44 27 17 13 11 8
10 711 533 356 213 133 89 53 33 27 21 15
15 1067 800 533 320 200 133 80 50 40 32 23
20 1422 1067 711 427 267 178 107 67 53 43 30
25 1778 1333 889 533 333 222 133 83 67 53 38
30 2133 1600 1067 640 400 267 160 100 80 64 46
35 2489 1866 1244 747 467 311 187 117 93 75 53
40 2844 2133 1422 853 533 356 213 133 107 85 61
45 3200 2400 1600 960 600 400 240 150 120 96 69
50 3555 2666 1778 1067 667 444 267 167 133 107 76
CalculationoflossesinAlcable
Cluster4:20households
Deltau(%)
0
10
20
30
40
50
60
1 5 10 15 20 25
Deltau(%)
Voltagedropalongcable
1,5mm 2,5mm 4 6 10 16 20 25 35
distanceinm
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Annex 3: Technical Specif ication of Main Equipment
1 Inverter with integrated Charge Controller
Inverter with integrated battery controller for the erection of 1- and 3-phase isolated
supply systems. Without transformer including current sensitive residual current
monitoring and tripping; including cooling/ventilation concept; single and three-phase
feed in including modular extension; including 2 seperate MPP-tracker for seperate
strings; multi-cluster operation. High efficiency, intelligent battery management to
optimize battery lifetime, calculation of battery load, high overlad capacity; with
integrated display and control unit; compatible to offered solar batteries; the inverter
must be suitableand fully compatbile to the offered solar modules;
Input (DC)
maximum DC output at cosphi = 1
max input voltage range 1,000 V
MPP- input voltage range 360 800 V
maximum input current 33 / 11 A
nominal output at 230 V
maximum AC appearent output
Battery Input
maximum DC output at cosphi = 1
rated input voltage 48 V
Input voltage range 41 V 63 V
max. battery charging current 110 A
DC rated charging current 90 A
DC rated de-charging current 103 A
Battery type gel battery
battery capacity range 100 AH 10.000 Ah
method of charge control
IUoU-charge with automatic full
charge and equalization charge
Oputput (AC)
Nominal AC voltage: 3 / N / PE 230 V / 415 V
Nominal AC voltage range 160 V .. 280 V
rated power frequency 50 Hz
rated power frequency range (adjustable) 45 Hz 65 Hz
Rated output power at nominal voltage and rated power frequency 25C / cosphi=1)
peak AC power at rated voltage and rated frequency at 25C for 30 min / 5 min / 3 sec
rated current
peak current
harmonic factor output voltage
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Standards
GeneralIEC 62103; IEC 60521; IEC
60721
Conformity CE or equivalent
General Data
Dimensions (W/H/D) describe
Weight describe
Operating temperature range -25C +60C
protection class (IEC 62103) I
protection class of connection area (IEC 60529) 3K6
Climatic category ( IEC 60721) IP54
Features
multifunction relay 2
3-phase systems /parallel connection yes / yes
integrated bypass
multicluster operation yes
calculation of charge condition / full / equalization charge yes / yes / yes
integrated soft start yes
generator support yes
battery temperature sensor yes
communication port, bluetooth yes / yesguarantee > 5 years
certificates and approvals describe
brand name and type name and model name describe
assembly describe
integrated graphic display yes
suitable for in- and outdoor installation yes
DC plug conncetors including DC load breaker yes
number of parallel strings minimum 5
Acce ssoires describe
2 Solar ModulesSolar Modules with crystaline solar cells, of high reliability with guaranteed 0/+5Wp
peak power classification; with IEC certificate; modul voltage, current and plug
connection; c onnection must fit to the offered Inverters; frame out of anodized
aluminium; frame with holow chamber profile and drainage opening; front made of
special hardened, high t ransparent glass, antireflective coated; weather proofed
terminal box at the rear; including necessary modul connectors made of flexible
copper isolated cables with connectors
Electric Data
rated power at standard temperature conditions
peak Power (Pmax)
peak voltage (Vmax)
peak sys tem voltage (VSmax)
Peak current (Imax)
short curcuit current (ISC)
no load voltage (VOC)
A/C-diagram
temperature coefficient; voltage (V/C)
temperature coefficient; power (%/C)
nominal cell operation temperature (NOCT)
U-I functions at 25C and other temperatures and radiation
General Data
minimum operational t emperature -40C +80C
minimum ambient temperature -40C +45C
Standards
connection terminal DIN VDE 0126-5
Wiring, plug connector EN 50521
Modules generalIEC 61215; IEC 61730;IEC
61701; IEC 61721; EN 50380
Certificates
Modules IEC 61215; IEC 61730
test report by a certified and licensed laboratory IEC/IEC 17025
product certification unit/authority acc. to EN 45011
CE conformity (or equal) yes
Guarantee
product guarantee 5 years for product
output guarantee 12 y ears,; minimum power output (% of nominal power) >90%
output guarantee 25 y ears; minimum power output (in % of nominal power)
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3 Support StructuresSupport structures acc ording to attached drawing no1 as support for the offered solar
modulesdescribe
4 OPZV Solar batterymaintenance free sealed lead-acid gel battery; sulphuric acid as electrolyte stabilized
as gel; including pole screws with isolated screw head and possibility to measure
voltage; including necessary connectors made of flexible isolated copper suitable for
maximum voltage and current; including end connectors with protection c over;
environmental friendly and full recyc lable
nominal voltage 2V
Min imum capac it y: C10, @ T=20C: 3050Ah; C100, @ T=20C: 3540 A h 3050 A h / 3540 Ah
Minimum Cycles at 80% / 50% Depth of Discharge (DoD): 1600 / 3000
operational temperature (minimum, maximum, optimum)
operation characteristic diagram
charge limit voltage including temperature dependancy
permissible c harge and -discharge current
permissible discharge depth
charge and discharge efficiency
self discharge in % per month
low voltage threshhold as function of disc harge current
Protectionintegrated Overvoltage yes
over current yes
short circuit yes
reverse polarity yes
Standards
General
IEC 60896-21; IEC 61427 or
similar
conformity CE or similar
Guarantee
product guarantee 5 years
cost free replacement at installation side in case the minimum output ratings fall shortyes
Features
Brand, Type, Model describe
dimensions (L / W / H) describe
modul dimensions (L / W / H) describe
weigth describe
characteristics of electrodes; construction, weave alloy describe
display of battery voltage describe
5 Batter ie supportfully isolated steel support suitable for the offered batteries; installation in strings per
support; if required in two lay ersdescribe
6 Documentations (for every component)description of component yes
connection plans yes
installation manual yes
commissioning regulations and procedures yes
operation manual yes
maintenance manual yes
failure analysis and proposals for measures to be undertaken yes
complete documentation in English and Urdu langauage 5 hard copies and 2 soft copies
7 After Sales Service
service point in District including description of experience available at service point;
services offered; available wear and spare partsdescribe
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Annex 4.1: System Report 5 households
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Battery maximum discharge power Inverter Output Power
Battery max.
discharge power
Inverter Output Power
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Excess Power PV Power Generation
Battery Charge Unmet Load
PV Power
Excess Power
Battery Stateof Charge
Unmet Load
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