POWER PLANTS AND WATER PUMPING SYSTEMS

FEATURES, SPECIFICATIONS AND TESTING

Dr. O.S.SASTRY
DDG-SPV TESTING
NATIONAL INSTITUTE OF SOLAR ENERGY (NISE)
Ministry of New and Renewable Energy (MNRE)
PH. 0124-2579213; Fax: 0124-2579207
e.mail: sastry284@yahoo.in

4/8/2014 “Effective Implementation of Solar PV programme ” 1

PV POWER PLANTS

“Effective Implementation of Solar PV programme ” 2

COMPONENTS OF STANDALONE
POWER PLANT

LOADS :
Domestic loads,
Hospital loads
Telephone Transmitters
Any other Loads
COMPONENTS OF GI POWER PLANT
COMPONENTS OF PV POWER PLANT

MAJOR COMPONENTS OF POWER PLANTS

 PV Modules

 Inverters/ PCU

 Battery Bank (stand alone/ hybrid system only)

 Array Junction Boxes(AJBs)

 Main Junction Box (MJB) for DC & AC

 Structures

 Cables

“Effective Implementation of Solar PV programme ” 5

SELECTION OF MODULE
TECHNOLOGY

6
 PV Module Performance & Qualification Standards

• STC performance IEC60904-1

• IEC 61215 (Revised) Crystalline Silicon Modules
• IEC 61853 Energy Rating
• IEEE 1262 (Crystalline & Thin Film Modules)
• JIS C 8917 (Crystalline Silicon Modules)
• IS 14286 : 1995 (Crystalline Silicon Modules)

• IEC 61646 (Thin Film Modules)

• 62108 Concentrator Photovoltaic (PV) receivers & modules design,

qualification and type approval

• 61730-I & II Module Safety Construction & Qualification

Latest Climatic Zone Classification criteria
 IEC 61853
23 Test Conditions: IEC 61853-1 standard (Introduced)

Isc, Voc, Pmax, Imax, Vmax at 23 sets of Irradiance and Temperature conditions

Irradiance Module temperature (0C)

(W/m2) 15 25 50 75
1100 NA 1 2 3
1000 4 5 6 7
800 8 9 10 11
600 12 13 14 15
400 16 17 18 NA
200 19 20 21 NA
100 22 23 NA NA
 Reference Conditions and Baseline Measurements
• IEC 60904-1 STC , IEC 61853 PV Module Performance testing and Energy rating
• IEC 82/686 for PID

• Conditions:
Performance at Standard Test Conditions (STC) [25°C, 1000 W. SqM]
Performance at Nominal Operating Cell Temperature (NOCT) [20°C, 800 W. SqM & 1m/ Sec Wind Speed]
Low Irradiance Condition(LIC) [25°C, 200 W. SqM]
High Temperature Condition(HTC) [75°C, 1000 W. SqM]
Low Temperature Condition(LTC) [15°C, 500 W. SqM]
Most Frequent Conditions (MFC ) ( Site and Technology Specific)

• Pre-Conditioning of Modules
- Depends on PV Technology ( Mono/Multi/ a-Si/CIGS/CdTe)
• Indoor measurements:
- Sun Simulator Class AAA:
Spectrum, Uniformity and Temporal Stability
Spire 240A/ Quick-SUN 700A/ Autosis (Class-B)
STC/ NOCT/ SoC/ Other Conditions
Spectral Mismatch / Temperature Correction
Scan rate and Direction ( Isc to Voc OR Voc to Isc)
• Outdoor Measurements:
- Radiation, Temperature and Spectrum Correction
- Radiation Intensity ~ 800W/ Sq. M
- Use of Accurate Temp. Coefficients

9/26/2014 12
 STC Measurements
Endas Quick Sun 700A simulator Spire sun simulator 240A

9/26/2014 13
Outdoor test set up used for measurements
The modules are then deployed in the outdoor and current-voltage (I-V) curve were measured at 5
minute interval, using PVPM2540, PV Engineering, Germany. To investigate the outdoor performance
the I-V data were filtered irradiance outside the range of 800 – 1000 W/m2. The angle of incidence is
low as the measurements are made between 11.30 AM to 1.30 PM
Most Frequent Conditions
 For m-Si
Irradiance (W/m2) Module temperature (0C)

15 25 50 75

Percenta Median Percenta Median Percenta Median Percenta Median

ge of Power ge of Power ge of Power ge of Power
Occurren (W) Occurren (W) Occurren (W) Occurren (W)
ce ce ce ce

1100 NA NA 0 0 0.014% 1400 0 0

1000 0 0 0.028% 1380 0.29% 1380 0.032% 1300

800 0.056% 1080 0.243% 1100 1.03% 1120 0.005% 1200

600 0.026% 820 0.173% 880 0.243% 820 0.002% 1000

400 0.03% 580 0.291% 600 0.33% 520 NA NA

200 0.101% 300 0.224% 280 0.06% 240 NA NA

100 0.12% 100 0.443% 100 NA NA NA NA

 For HIT
Irradiance (W/m2) Module temperature (0C)

15 25 50 75

Percent Median Percent Median Percent Median Percent Median

age of Power age of Power age of Power age of Power
Occurr (W) Occurr (W) Occurr (W) Occurr (W)
ence ence ence ence
1100 NA NA 0 0 0.017% 1500 0 0

1000 0 0 0.015% 1460 0.144% 1520 0.004% 1500

800 0.003% 1220 0.31% 1260 2.28% 1260 0 0

600 0.016% 960 0.4% 980 0.88% 920 0 0

400 0.104% 660 0.663% 660 0.3% 560 NA NA

200 0.362% 280 0.347% 280 0.046% 260 NA NA

100 0.172% 120 0.332% 120 NA NA NA NA

 For a-Si
Module temperature (0C)
15 25 50 75
Perce Median Percent Median Percent Median Percent Median
Irradiance (W/m2) ntage Power age of Power age of Power age of Power
of (W) Occurr (W) Occurr (W) Occurr (W)
Occu ence ence ence
rrenc
e
1100 NA NA 0 0 0.007% 1100 0 0

1000 0 0 0.003% 1020 0.08% 1040 0 0

800 0 0 0.003% 840 1.63% 820 0.043% 840

600 0 0.002% 580 1.54% 640 0 0

400 0.002 0.063% 360 0.79% 420 NA NA

%
200 0.035 0.23% 180 0.19% 180 NA NA
%
100 0.09% 0.24% 80 NA NA NA NA
 Chennai(Warm and Humid) 35000
18000
Actual Rh range: 35-100% TEMPERATURE
16000 30000 Actual Mod tem range: 25-
Zone Classification: >75% 40°C
14000 As Per IEC 61215 : 85% ±5% 25000
Zone Classification: >30°C
12000
20000
10000 HUMIDITY
8000 15000
6000
10000
4000
2000 5000

0 0
5 15 25 35 45 55 65 75 85 95 5 10 15 20 25 30 35 40 45 50 55 60

Mod temp : 25-60°C, mc-Si mod temp: 25-65°C , a-Si mod temp: 25-65°C
As Per IEC 61215 :65°C±5%

Module Temp- HIT Mod Temp-mc-Si Mod Temp-a-Si

5000
6000
7000
4000 5000
6000
5000 3000 4000
4000 3000
2000
3000 2000
2000 1000
1000
1000
0 0 0
5 101520253035404550556065707580 5 101520253035404550556065707580 5 101520253035404550556065707580
 Jodhpur (Hot & Dry)
Actual Mod tem range: 5-
4500 Actual Rh range: 5-100% 45°C
4000
Zone Classification: >75% 9000
Zone Classification: >30°C
3500
As Per IEC 61215 : 85% ±5% 8000
7000
3000 6000 TEMPERATUR
HUMIDITY
2500 5000 E
2000 4000
1500 3000
2000
1000
1000
500
0
0
5 10 15 20 25 30 35 40 45 50 55 60
25
5
10
15
20

30
35
40
45
50
55
60
65
70
75
80
85
90
95
100

Mod Temp
2000
1800
1600 Actual Range 5-75°C
1400
1200
1000
800
600
400
200
0
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
 GHI-Chennai 5000

3500
4500 DNI-Chennai
4000
3000
3500
2500 3000
2000 2500
1500 2000
1500
1000
1000
500
500
0
0
100 200 300 400 500 600 700 800 900 1000 1100
100 200 300 400 500 600 700 800 900 1000 1100

GHI-Jodhpur 5000
DNI-Jodhpur
4500
3000
4000
2500 3500
2000 3000
2500
1500
2000
1000
1500
500 1000
0 500
100 200 300 400 500 600 700 800 900 1000 1100 0
100 200 300 400 500 600 700 800 900 1000 1100
 Comparative Test Standard Matrix
• PV Manufacturers prefer descriptive ratings rather than grades.
• Acceptable to rate modules for different climates.
• Use IEC 60721-2-1 to establish several climate zones for rating
modules.
• Add mounting conditions as this impacts operating temperatures.
IEC 60721-2-1 Climate
Mounting classes
Designation

Rack mount Close-roof mount

Moderate (Temperate) ✔ ✔

Warm Damp, Equable

✔ ✔
(Tropical)
Extremely Warm Dry
✔ ✔
(Desert)

Source:
“Development of Comparative Tests of PV Modules by International PV QA Task Force”,
by John Wohlgemuth , Sarah Kurtz, Tony Sample, Michio Kondo and Masaaki Yamamichi
 PROPOSED RATING SYSTEM

Source:
“Development of Comparative Tests of PV Modules by International PV QA Task Force”,
by John Wohlgemuth , Sarah Kurtz, Tony Sample, Michio Kondo and Masaaki Yamamichi
 Flow Chart of Proposed Comparative Test Plan

modules modules module Material Test

UV Test**

Climate Mounting Class

Is -40°C Relevant for Most of Indian Sites? Rack Roof
Moderate T1 = 60 °C T1 = 80 °C
RH = 85% RH = 85%
X = 500 h X = 500 h
Warm Damp T1 = 80 °C T1 = 80 °C
RH = 85% RH = 85%
X = 1000 h X = 1000 h
Hot Dry T1 = 80 °C T1 = 100 °C
RH = 40% RH = 40%
X = 1000 h X = 1000 h

Source:
“Development of Comparative Tests of PV Modules by International PV QA Task Force”,
by John Wohlgemuth , Sarah Kurtz, Tony Sample, Michio Kondo and Masaaki Yamamichi
 SELECTION OF
INVERTERS/ PCU

27
TYPES OF INVERTERS USED IN PV POWER PLANT

MAJOR COMPONENTS OF POWER PLANTS

 Stand-alone up to 25KVA

 Hybrid Inverters (SMD Type)

 String Inverters 1 to 20 KVA

 Large capacity Centralized GI Inverters

 Major Features Of Inverters:

 Modes of Operation
 System Voltage and polarity
 Power Factor and Reactive power
 Efficiency Vs Load performance
 MPPT range
 Protections
 Environment and IP certifications

“Effective Implementation of Solar PV programme ” 28

Standards Followed:
Performance Evaluation: IEC 61683
Islanding Protection: IEC 62116
Characteristics of Utility interface: IEC 61727
Environmental: IEC 60068-2–(1, 2, 14, 30):
Ingress Protection(IP): IEC 60529 (IP65(out door ),
IP 21(indoor)
Grounding: Equipment/ DC/ AC
 Testing of Inverter consists of
following tests:
• Performance evaluation
of the sample at
different type and
percentage of load
• Charge controller
efficiency
• Modes of operations
• AC & DC cut off limits of
parameters
• Protections settings
Inverters Test set-up at NISE
Maximum reachable efficiency
MPPT SELECTION

33
COMPONENTS OF PV POWER PLANT

MPPT Features

 Operation Range

 Speed of Operation/ Algorithms

 Efficiency

 Polarity/ Connection

“Effective Implementation of Solar PV programme ” 34

COMPONENTS OF PV POWER PLANT

AJBs & MJBs

 Use of Proper Cutouts

 Blocking Diodes of proper rating

 Fuses

 Surge Arresters

“Effective Implementation of Solar PV programme ” 35

COMPONENTS OF PV POWER PLANT

Module Mounting Structures Features

 Ground or Roof Mounting

 Fixed Tilt or Seasonal Tilt or manual or auto tracking

 Material ( Al or Hot Dip GI or Steel) used structures (nut & bolts)

 Clamping of Modules

 Shadowing

“Effective Implementation of Solar PV programme ” 36

INSTALLATION STANDARDS OF PV POWER PLANT

MAJOR STANDARDS/ CODES

 IEC 62738 Design and Installation Guidelines

 NEC Applicable for the country

 IEEE 1547 Interconnection of distributed sources

 UL 1741 for Inverters and converters connection

 IEC 61724

 IEC 60364-9-1 Safety of PV Power Plants

“Effective Implementation of Solar PV programme ” 37

SPV WATER PUMPING SYSTEMS
Think yourselves

Pumping systems account for nearly 20% of the

world’s electrical energy demand and range from
25-50% of the energy usage in certain industrial
plant operations.
JNSM Proposes the installation of 10 Lakhs
Solar Pump sets in the country
Main Objectives:

 Understanding Solar PV water pumping system

 Understanding Different components of SPV water pumping

system

 Understanding Designing of SPV water pumping system

 Understanding Testing of Solar photovoltaic pumping system

at NISE
Solar PV water pumping system:

To lift water through motor driven pumps using solar energy by

solar photovoltaic route.
Components of Solar Photovoltaic Water
Pumping System
 Solar Photovoltaic Pumping systems has following components:

 PV array which converts solar energy

to DC electricity .
 Mounting structure of PV array can
have manual as well as automatic
tracking.
 Motor and pump subsystem
comprising the components which
convert the electrical output of the PV
array into hydraulic power.
 MPPT /DC-DC Converter/ VFD based
controllers enhance the system output.
 Storage and distribution system
which delivers the water to its point of
use
General types of Pumps
 Types of Pumps currently used in
Solar water pumping system
 Surface centrifugal pumps
 Submersible Centrifugal
 Submerged pump with helical
rotor arrangement below the
water
 Floating motor/pump units
with centrifugal pump
General types of Motors
Types of Motors currently used in
Solar water pumping system
Brushed type permanent magnet DC motors
Brushless permanent magnet DC motors
AC motors
Permanent magnet AC motors
 Newer versions use a variable frequency drive (VFD)
3 phase pump controller driven AC motor.
 Controllers/Inverters:
 MPPT/ DC-DC/ Constant Voltage Converter based controllers
can be used to run the pump at maximum flow rate.
 Controllers also provide protection in situations of dry
running, open circuit, short circuit and reverse polarity
 In case of AC pumps, VFD based inverters are used
 Purpose of VFDs (Variable Frequency Drives):
• Run a pump at a desired speed
• Use power efficiently to produce the necessary torque at a
given speed.
• Better regulation
• Increased overall energy efficiency
General SET-UP of solar PV Pumping system Operation
DESIGNING OF SPV WATER
PUMPIMG SYSTEM
7 Steps in Designing of Solar water pumping
system
1. Solar Insolation: For a particular site collect published
data/maps and conclude average daily solar irradiation (kWh/m² )
through out the year to create TMY. For example in Delhi we
take 5.5kWh/m² at horizontal which means 5.5 full sun shine
hours.

2. Your daily water requirement (V):

Generally we may consider
 Household- 50 gallons per day per person (average)
 Young Trees- 15 gallons per day in dry weather
 Cattle and Horses- 10-15 gallons per day per head
 Sheep and goats- 2 gallons per day
 Dairy Cows- 20-30 gallons per day
 Poultry- 6-12 gallons per day per 100 birds
3. Irrigation requirement varies crop to crop and method of
irrigation like sprinkling, dripping or flooding.
3. Water Source Information:
 Surface water: Pond, Canal, stream?
 Well: Drilled or dug? Static and Dynamic water level?
 Water Quality: Colloidal clay, sand, silt or other debris
present?
 Water Depth: Shallow (around10- 12 meters) or Deep (more
than 70 meters) ?

4. Choose Pump Type:

 Surface type pump for ponds, springs and streams: Suction lift
is around 7 to 10 meters. Quantity of water very high
 Submersible type pump for wells more than 15 meters in depth.
 Submersible pumps can also used for some surface water
applications where high volume and/ or high lift is required.
5. Calculate Total Dynamic Head (H):
 =Suction head + Discharge head + Friction losses.
 Friction losses are different for steel and plastic pipes.
 To calculate friction losses a certified data table may be considered
6. Sizing the pump and motor:
 Calculate Hydraulic Energy (E) used to deliver a volume (V) of
water
E = (ρV) X g X H

E - hydraulic energy in Joules

V - volume of water in cubic metres (m3)
H - total Dynamic head in metres
ρ - density of water (1000 kg/m³)
g = 9.81 m/s

 Pump shaft power = Hydraulic Energy(E) / Full sun shine

hours/pump efficiency
 After calculating pump shaft power we can calculate input
power needed to run pump after considering power factor of
motor
 While doing all above calculations it is advisable to refer
manufacturer‟s data sheet
 Pump efficiency is entered as a decimal (e.g., 65% is entered
as 0.65) - if the pump efficiency is not known, choose a
conservative 50%
 The horsepower calculated must be „rounded-up‟ to a standard
motor size (e.g., a calculated 0.8 hp would be rounded-up to
1 hp)
7. PV Array sizing:
Before calculating array size for powering motor, it is better to
know irradiance pattern and temperature pattern at the site.
 From graph we can estimate array size by considering
irradiance 700-800W/m² for NISE site and also we can
increase array size in consideration of temperature losses (45-
50°C for mc-Si).
 Depending upon the input range of selected pump of required
power, the number of modules in series and parallel can be
arranged.
Percentage of Average Annual Solar Energy in different
irradiance ranges received at NISE (2010-2013)
20

18
Percentage in terms of irradiation (%)

16

14

12

10

0
0 0 0 0 0 0 0 0 0 0 0
0-20 0-30 0-40 0-50 0-60 0-70 0-80 0-90 -100 -110 -120
5 20 30 40 50 60 70 80 00 00 00
2 9 10 11
Irradiance (W/m )
 Percentage of Average Annual Energy generated by different
technology modules under their different temperature ranges
20
at NISE (2010-2013)
18

16

14
Percentage (%)

12
a-Si
10 HIT
8 m-Si
6

Module Temperature Range (0C)

Points to be remembered while designing :

The pump performance parameters (flow rate, head, power)

will change with varying rotating speeds. The equations that
explain these relationships are known as the “Affinity Laws”:

 Q (Flow Rate) α N (Rotating speed)

 H (Head) α N²
 P (Power) α N³
Manufacture data sheet for selecting
head
Flow Rate Versus Input Power
Flow Rate Versus Input Power
Efficiency Versus Power
Testing Facility of Solar photovoltaic pumping
system at SEC
Performance Evaluation of SPV water pumping system

Two test beds

1. At 7 meter static head
2. At 3 meter static head
The total Dynamic head of
pump is maintained by using
pressure gauge before flow
meter.
 Pyranometer
Flow meter Pressure Gauge

Data Acquisition system

with transducers for voltage Test set up
and current measurement
Quality Testing of PV Water Pumping System
TYPE OF PUMPS
 DC Surface (Centrifugal) Pumps
 DC/AC Submersible Pumps
 Float Pumps ?
SPECIFICATIONS
 IEC 62253 & 61702 AND MNES Performance Guidelines 2006-07
INSTRUMENTATION
 Deep Sump Well
 PV Array
 PV Array Testers
 Data Loggers with sensors
 Flow & Pressure Gauges/Meters
Main Quality Indicators
 Throughput - Liters/watt/day
 Average Wire to Water efficiency
 Peak Efficiency
 Relevant Standard

 IEC 62253: Direct coupled Photovoltaic pumping systems-

Design qualification and performance measurement

 IEC:61702:Rating of Direct coupled photovoltaic pumping

system

 New PV Pump standard under development !!!

 JNNSM, MNRE-2013-14 Technical specifications for shallow well
(Surface) Solar pumping systems with D.C. motor pump set with brushes
or brushless D.C. (BLDC)
 JNNSM, MNRE-2013-14 Technical specifications for Deep well
(Submersible) Solar pumping systems with D.C. motor pump set with
brushes or brushless D.C. (BLDC)
 JNNSM, MNRE-2013-14 Technical specifications for shallow well
(Surface) Solar pumping systems with A.C. Induction motor pump
set and a suitable inverter
 JNNSM, MNRE-2013-14 Technical specifications for Deep well
(Submersible) Solar pumping systems with A.C. Induction motor
pump set and a suitable inverter
Comprehensive test report of Solar PV pumping
system issued by SEC contains

 Wire to water efficiency of pump at a particular head

 Liters per watt peak per day at 7.15kWh/m² at a particular
head
 Temperature Correction on PV Array
 Array capacity at STC
 I-V Curve of each module of array
 Suggestions to improve the system.
 WHAT ARE THE MAJOR CONCERNS ?

• MAIN PROBLEMS ARE :

- MATCHING OF PUMP AND PV ARRAY

- EFFICIENCY OF MOTOR AND PUMP

- PV ARRAY STRUCTURES

- PROTECTIONS ( DRY RUNNING, GROUNDING, DC SHOCK etc.)

Performance curves of a Water pumping system (Centrifugal
surface DC pump) tested at NISE: Capacity:2HP, Array Size:1.9kWp
Performance curves of a Water pumping system (Centrifugal
surface DC pump) tested at NISE: Capacity:2HP, Array
Size:1.9kWp, Head:10 meters

6.65
6.30
5.95
5.60
System efficiency (%)

47.6
44.8
42.0
Wire to water efficiency (%)
39.2
1400

1260

1120 Input Power (W)

980
22.4
19.6
3
16.8 Flow Rate (m /hour)
14.0
876
803
730
657 2
In-plane Irradiance (W/m )
0 0 0 0 0 0 0 0
09:0 10:0 11:0 12:0 13:0 14:0 15:0 16:0
Time
Performance curves of a Water pumping system (Submersible
AC Pump) tested at NISE: Capacity:5 HP, Array Size:4.7kWp,
Head: 50 meters

7.7
6.6
5.5
System efficiency (%)
4.4

60.2
51.6
43.0
Wire to water efficiency (%)
34.4

12.4
9.3
3
6.2 Flow Rate (m /hour)
3.1
3660
3050
2440 Input power (W)
1830
960

800

640

480 2
In plane Irradiance (W/m )
0 0 0 0 0 0 0 0
09:0 10:0 11:0 12:0 13:0 14:0 15:0 16:0
Time
Performance curves of a Water pumping system (Submersible
AC Pump) tested at NISE: Capacity:5 HP, Array Size:4.72kWp,
Head: 50 meters

7.7
System efficiency (%)
6.6
5.5
4.4

67.5 Wire to water efficiency (%)

60.0
52.5
45.0
3120
2860
2600
Input power (W)
2340
2080
14
12
10
3
8 Flow rate (m /hour)

840
720
600 2
In plane Irradiance (W/m )
480

0 0 0 0 0 0 0 0 0 0 0
07:0 08:0 09:0 10:0 11:0 12:0 13:0 14:0 15:0 16:0 17:0
Time
 Pros and Cons of Solar Water Pumping

PROS CONS

• Reliable and long life • Potentially high initial system

• Produces water during sunny cost, therefore needs subsidy
weather when it’s needed (but now cost is declining)
most • Water pumped only during
• Low labor and maintenance day or Decreased water
costs production in cloudy weather
• No fuel costs • Water storage and/ or
• Easy to remove, transport, battery needed for providing
and store full time water
• Non-polluting • Must have good sun
exposure between 9 am and
3 pm
Economy and Reliability:

 If your water source is 1/4 km or more from the power line,

solar is a favourable economic choice.
 Highly Economical compared to diesel pumps
 The fuel is free
 A few spare parts can assure you many years of reliable water
supply at near-zero operating costs.
 Solar power and water pumping are a natural fit. As water is
needed most when the sun is shining at its brightest.