This report includes all required technical details, financial assessment with Net Cash Flow from 1MW Solar PV project in India. From selection of Solar PV panels, inverters to selection of Isolator, grid synchronization & grid evacuation voltage, all detail can be found in this report.
Queries@ [email protected]Detail Project Report 1MW p SPV Power Plant www.renewpowerzone.in Page 1 Acknowledgement This analysis based report is done for the readers of my previous report 1MW Utility Scale SPV Power Plant, mainly for the readers from South region of INDIA as they are asking repeatedly about the probability and feasibility-technical & Financial-of a SPV power plant in their region. At the same time it’s not possible for me to design a report for each and every state from South India, so I took Chennai city. Also the previous report was not so detail, was very basic and meant to the readers who want to get an overview on how a utility scale power plant works. Now, in this report, I discuss about in depth. From panel’s selection to CB sizing all are presented in very detail. Hope, this time you get a strong knowledge on designing and estimation of 1MW solar PV power plant. Unlike the previous report, the financial aspect discussed at the end of the paper. In this paper, the financial assessment has done in very detail and considering the current scenario of SPV market including the cost of solar PV modules, inverters’ cost, cable, transformer etc. prices and the funding, interest rate. And if you have any queries or need clarification, please contact at [email protected]or [email protected]. Disclaimer The presented data here are NOT TAKEN from any copyright materials and not showing under my name. The meteo data collected from NASA website and NREL database which is free over the internet. Designing of PV system is totally based on the practical experience of the author. Assumption & Consideration Shading consideration: No shading has been considered at the site during the calculation design. So it is advised that at the time of execution, please check whether there is any kind of obstacle in the site which may cause partial/full shading on PV strings and/or PV array. If the shading occurs, then the estimated power generation will not match the actual power generated. Load Factor: It is assumed that the produced power from the PV plant will be fed to the local utility grid. So, while designing the system, no unbalanced load considered in 3 phase configuration. Meteo data: The calculation based on the meteo data collected from NASA website which is very reliable. Now, based on the co-ordinates the values have been presented in this report. So, total design is based on this data. For a different location (coordinates), the system design will differ. It is advised not to copy and implement the design without consulting the author or any certified PV professional because this design estimation is valid only for a particular site.
This analysis based report is done for the readers of my previous report 1MW Utility Scale SPVPower Plant, mainly for the readers from South region of INDIA as they are asking repeatedlyabout the probability and feasibility-technical & Financial-of a SPV power plant in their region.At the same time it’s not possible for me to design a report for each and every state from SouthIndia, so I took Chennai city. Also the previous report was not so detail, was very basic andmeant to the readers who want to get an overview on how a utility scale power plant works.Now, in this report, I discuss about in depth. From panel’s selection to CB sizing all arepresented in very detail. Hope, this time you get a strong knowledge on designing andestimation of 1MW solar PV power plant. Unlike the previous report, the financial aspectdiscussed at the end of the paper. In this paper, the financial assessment has done in very detailand considering the current scenario of SPV market including the cost of solar PV modules,inverters’ cost, cable, transformer etc. prices and the funding, interest rate.And if you have any queries or need clarification, please contact at [email protected][email protected] .
DisclaimerThe presented data here are NOT TAKEN from any copyright materials and not showing undermy name. The meteo data collected from NASA website and NREL database which is free overthe internet. Designing of PV system is totally based on the practical experience of the author.
Assumption & Consideration
Shading consideration: No shading has been considered at the site during the calculationdesign. So it is advised that at the time of execution, please check whether there is any kind ofobstacle in the site which may cause partial/full shading on PV strings and/or PV array. If theshading occurs, then the estimated power generation will not match the actual powergenerated.Load Factor: It is assumed that the produced power from the PV plant will be fed to the localutility grid. So, while designing the system, no unbalanced load considered in 3 phaseconfiguration.Meteo data: The calculation based on the meteo data collected from NASA website which isvery reliable. Now, based on the co-ordinates the values have been presented in this report. So,total design is based on this data. For a different location (coordinates), the system design willdiffer. It is advised not to copy and implement the design without consulting the author or anycertified PV professional because this design estimation is valid only for a particular site.
Site consideration: this design has been done by considering the PV modules & array will beground-mounted and the site-elevation angle taken 30 .
Cost Estimation: 1MW Solar PV power plant cost estimation has done considering the currentPV market scenario (Sept-Dec 2013), so after few months the cost may vary according themarket.CAD design & layout: I have not uploaded/attached the CAD design. If anybody interested insetting up the plant then only contact at the given e-mail ids to get the design file.
Transmission & wheeling losses: Here, in this report, while doing the technical assessment, thedistance from nearest substation to the 1MW solar PV power plant taken within 1.5 KM and sothe wheeling losses considered as 3% of total power transmission. And in the financialassessment, no wheeling charges have been considered.
Design Criteria: While designing & estimating the technical components & solutions, all therequired/applicable standard design codes have been considered. Mainly the IEC (InternationalElectrotechnical Commission) Codes, IS codes from BIS have been considered thoroughly.
IntroductionIndia is densely populated and has high solar insolation, an ideal combination for using solar power inIndia. India is already a leader in wind power generation. In the solar energy sector, some large projectshave been proposed, and a 35,000 km2 area of the Thar Desert has been set aside for solar powerprojects, sufficient to generate 700 GW to 2,100 GW. Also India's Ministry of New and RenewableEnergy has released the JNNSM Phase 2 Draft Policy, by which the Government aims to install 10GW ofSolar Power and of this 10 GW target, 4 GW would fall under the central scheme and the remaining 6GW under various State specific schemes.
The Electricity Act, 2003, paves way for an innovative approach to solve our country’s power problems.It has paved the way for a competitive environment; open access to existing transmission anddistribution network to transmit electricity across regions; de-licensing of generation, captive power anddedicated transmission lines; licensing of distribution and supply companies and the restructuring ofState Electricity Boards.
The Ministry of Power has mandated to promote cogeneration and renewable sources for Powergeneration under Nodal agencies and hence it will play a major role in mainstreaming renewable energysector. The advantage or renewable resources includes their capacity to produce energy withoutproducing carbon-based warming and polluting agents into the atmosphere. The financial cost of itsapplications is not always cheap but if the environmental costs of using fossil are accounted for,renewable energy wins hands-down. There are also indirect savings on health and its costs as there areno harmful emissions.
In the above backdrop, YOUR COMPANY NAME has decided to set up a 1/1000 MW/KW Solar PowerPlant. This Detailed Project Report (DPR) brings out all technical details and overall costs justifying theselection of the project. The total power generation is envisaged to be 1050KW from Solar PhotovoltaicCell. It is a very important document that is required for Environmental Impact Assessment (EIA) studies,fixation of tariff, finalizing Power Purchase Agreement (PPA) and also for submission to FinancialInstitutions for obtaining project funding. The total project cost is expected to be Rs ___ Crores and theaverage cost of generation is expected to be Rs. 7.5/kWh (ASSUMED).
For this project, poly-crystalline technology based 3rd generation Solar PV modules will be used. Alongwith this, highly efficient, photon-tested string inverters going to be integrated to the system. Thesetechnologies are the best in the industry. So, It’s clear that our project is not compromising with thequality of the materials and or the components which obviously led this project to success.
* Here, 120 angle at AM1.5 has been chosen as fixed south faced model for the project
Winter
56° angle
Spring/Autumn
80° angle
Summer
104° angle
On the 21st December, the sun will rise 87° east of due south and set 87° west of due south.On the 21st March/21st September, the sun will rise 91° east of due south and set 91° west of duesouth.On the 21st June, the sun will rise 95° east of due south and set 95° west of due south.
Solar PV Array Sizing & Connection Detailsconditions At STC (250C) At Avg. Ambient temp. (280C)Suggested array Size 1100 KWp 1100KWp
Actual Solar PV Array Size 1082KWp 1100KWp
Watt Peak of each SPV module 250Wp 263WpTotal nos. of SPV modulerequired
4326 4326
Total nos. of strings 206 206Nos. of SPV modules in eachstring
21 21
SPV connection in each string Series SeriesString voltage (VMPP) 609V 630VString current (ISC / IMPP) 8.87A/8.3A 9.51A/8.82AConnection of strings Parallel ParallelArray voltage (VOC / VMPP) 780V/635V 750V/620VArray current (ISC / IMPP) 1830A/1710A 1960A/1816A
Detail Solar Inverter Specification & Design Details
Inverter Type String Inverter (MPPT)Quantity 53INPUT (DC)Max. Power 23KW
Max absolute Input Voltage 1000VStart Voltage 350VNominal MPP voltage range 490V-800V
Max Input Current per string 41.5ANos. of Independent MPP inputs/stringsper MPP inputs
1/6
OUTPUT (AC)Rated Output Power 20000WMax. Apparent AC Power 20000VAPower Threshold 20WNominal AC Voltage/range 3/N/PE;230/460VAC Power Frequency/ range 50HzMax. output current 3x29APower factor at rated power 1Feed-In phases/connection phases 3/3EfficiencyMax. Efficiency 98.7%Protection DetailsDC Disconnect AvailableDC Surge Arrester AvailableProtection Class I (as per IEC 62103)Total harmonic distortion <1.8%Operating Temperature range -25◦-60◦CNoise Emission <35dBSelf Consumption <25WCooling option Forced Air-cooledProtection type IP65 (as per En 60529)Remote Monitoring SystemUser Interference & Communication
With RS-485/Ethernet
Electrically Isolated relay output AvailableStatus Display AvailableInverter to inverter communication AvailableAnti-islanding protection AvailableInverter connection detailsTotal nos. of inverter 53Nos. of strings per inverter 4Connection of strings/inverter ParallelInter-inverter connection Parallel into Cu busbarInter-Inverter isolator Provided
Transformer SizingDesign Criteria IS-2026 / IEC-60076Transformer type Power transformer, core type with oil-immersed ;
650C winding temp riseCooling type ONAN(Oil Natural Air Natural)Rated KVA 1250KVAHigh Voltage rating 11000VLow Voltage Rating 460VNominal impedance 4.7%Impedance tolerance 7.5%Nominal secondary amps 1250AMax SC withstand current 20KA/3sHV connection DELTALV connection WyeOperating frequency 50HzTap changer ±5% of full load capacity
Protective devices
components Specification QuantityDC Disconnects String to inverter= 1000V, 15A; 2 pole
DC Side Cables (strings to inverter)Design criteria IEC-60811 & IEC-60216Cable material CopperSingle cable length per string to inverter 70 ftCross section per string 4 mm2
Voltage drop 0.18VRelative power loss reference to Max DC power 0.07%Max withstand temp. Normal condition Short-circuited
condition900C 2500C
Max withstand current capacity 42KA/1secConductor type StrandedInsulation material XLPELT Cables (Inverters to busbur/distribution panel)Design criteria IEC-60228 & IEC-60811Cable material CopperMax Single cable length per inverter to panel box 60 ftCross section 16 mm2
Voltage drop (3phase) 0.46VRelative power loss reference to Max AC nominalpower
0.23%
Max withstand temp Normal condition Short-circuitedcondition
900C 2500CMax withstand current capacity 2KA/1secConductor type StrandedInsulation PVCHT Cables (from distribution panel to feed-in point)Design criteria IEC-60502Cable material AlCable length from distribution panel to feed-in point
25 ft
Cross section 185mm2
Voltage drop (total) L1 1.37VL2 1.37VL3 1.37V
Relative power loss reference to Max ACpower
0.57%
Voltage grade 11KV(UE), heavy dutySC withstand current capacity 26KA @1sInsulation XLPE
•Preparation of design & estimation of the plant•15 working days required.
Landacquisition
•As per design requirement, proper land selection & acquisition processed.•Time required 1 month
PPA
•Power Purchase Agreement(PPA) with private power purchaser need to be finalized at a feasible rate.•Required time is 15 working days
DPR
•Preparation of Detailed Project Report including technical feasibility of the project prepared.•Time required 6 working days.
finance
•Arrangement of finance/fund for the project from nationalized or private financing agency with significant interest rateand equity share will be finalized.
•Required time for this stage is 1 month.
procurement
•After finalizing PPA and arrangement of fund for the project, procurement work starts including preparation & finalizing ofvendor selection, BOM, BOQ, order placing, follow-ups of delivery to site/warehouse.
•Estimated time for this step is 1 month.
construction
•After the processing of procurement, first civil construction at the site starts for PV mounting structure set-up andcontrol-room, administrative building. Finishing the civil works, PV installation & all electrical construction works includingthe Grid Evacuation will be processed.
•Estimated time for this whole work is 2 months.
commissioning
•Commissioning of the plant by authorized govt. body or certified 3rd party will be done followed by Completion of projectexecution.
Why do we need an O&M for Solar PV power plant?As every plant needs a regular maintenance work to make it functional & in well-condition, soin this case also, a PV power plant also requires a sound & efficient operation & managementteam to perform all the work after plant commissioning.A detailed structure of O&M team has been provided here in a hierarchy model to demonstratein a simpler way.
Initial Investment in terms of components’ cost & service charges
Sl.No.
Components/services Total cost(in INR)
Remarks
1. Solar PV modules 45,100,000 41rs/Watt peak2. Solar inverters 11,660,000 11rs/Watt peak3. Transformer 2,940,000 From international vendor4. Protective devices 1,200,000 From international vendor5. Wires/Cables 1,000,000 Considering IEC codes & ISO
certified6. SCADA/RMS 1,000,0007. Project execution & commissioning 2,000,0008. Construction works 4,000,0009. Grid evacuation 1,000,000 (assumed) Assumed because of having
no sufficient data10. Other official works 1,000,000 Subject to change as per
rulesTotal Project investment 70,900,000 INR
Total expenses over the year for plant O&M and staffing = 2,000,000This expense is considered for regular maintenance cleaning of PV array, checking the status ofinverter, cable-fault checking, emergency maintenance & replacement of components andannual salaries of O&M team of the plant.
Loan Interest rate is @12% over 70% of total project cost which shall be completed within next7 years (the rest 30% as equity shares).
Estimated time period 7 years 10 yearsTotal Loan amount 49,630,000 49,630,000Interest rate 12% 12%EMI 876,110 712,050Monthly interest 285,270 298,460total Interest paid 23,962,830 35,815,600
Net Cash Flow/year Estimation (all amounts are in INR)Initial Investment 70,900,00Expenses for O&M per year 2,000,000Total amount paid/year for loan(7 years termconsidered)
10,513,320
Tolerance factor 2%Total amount to be paid per year 12,763,600Energy generated per year 1,655MWhPPA rate for next 12 years 7.5rs/KWhREC floor price 12,000rs/MWh (approx.)Gross cash flow through PPA 12,412,500Gross cash flow through REC trading 19,860,000Net Cash Flow (NCF) per year 21,759,180
I’d like to thank you for reading the whole paper. Hope you have got clear view on design &estimation of 1MW utility scale Solar PV Power Plant. Though I have discussed about thetechnical part as well as the financial part in detail, I might have been forgot to add anythingmore important. So, you are most welcome to give your valuable feedback & suggestion on thisreport. At the end, I discussed about some companies for the components. I have chosen thesecompanies because their products are fulfilling my design criteria. It is not that I’m representingthese companies and their products.
About Myself: I’m a Solar PV professional currently working with a solar EPC company asProject Engineer. I’ve done B.Tech in Electrical Engineering & holding a PG certificate inAdvanced Solar Energy from delft Technical University, Netherlands.
Personally I provide technical consulting including site survey, technical design, CAD design,preparation of DPR, guide in procurement & Construction.
You can review my papers/reports at www.wbut.academia.edu/amritmandal
Connect to my professional profile in linkedIn at –http://www.linkedin.com/pub/amrit-mandal/55/667/a3
Read solar PV related articles & learn about new technologies at- www.renewpowerzone.in
