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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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Development and Usage of Hydropower and Renewable Energies inKhyberPakhtunkhwa, Pakistan

Technical Guidelines & ReportsVolume 4: Design of PV Community Systems

Hydropower Implementation Aspects - 1 -

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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s

1 Avergagehousesize

(rooms) 2 20

2 AirCoolingFan 1 10

3 OutsideLighting 1 2



(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




6 2.775

12.025


Clusterof5houses

A.Data

Rational

1lightperroom

1fanPerhouse

1street

light

per

cluster

of

5

houses

B EnergyDemand




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Annex 1.3: Cluster 3:- 15 households



s

1 Avergagehousesize

(rooms) 2 30





(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




6 4.158

18.018


Clusterof5houses

A.Data

Rational

1lightperroom

1fanPerhouse


houses

B EnergyDemand




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s

1 Avergagehousesize

(rooms) 2 40





(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




6 5.546

24.031


Clusterof5houses

A.Data

Rational

1lightperroom

1fanPerhouse


houses

B EnergyDemand

TheFudgeFactor@30%(SystemLossesforACpowerPVsystem)



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Annex 2: Voltage Drops in Cables


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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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



Deltau(%)

0

5

10

15

20

25

30

35

40

1 5 10 15 20 25 30 35

Deltau(%)


1,5mm 2,5mm 4 6 10 16 20 25 35

distanceinm

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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



Deltau(%)

0

5

10

15

20

25

30

35

40

45

1 5 10 15 20 25

Deltau(%)


1,5mm 2,5mm 4 6 10 16 20 25 35

distanceinm

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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



Deltau(%)

0

10

20

30

40

50

60

1 5 10 15 20 25

Deltau(%)


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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Battery max.

dischargepower

Inverter OutputPower

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PV Power

Excess Power


Unmet Load

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Battery max. discharge power

InverterOutput Power

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PV Power

Excess Power

BatteryState ofCharge

Unmet load

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Battery max. discharge power

Inverter OutputPower

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Unmet Load

PV Power

Excess Power

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Documents

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