1

VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana Sangama, Belagavi – 590 018.

An Internship Report
On

“Solar Water Pumping Systems”

Date (10.3.2021) – Date ( 31.10.2021)
Submitted in partial fulfilment of the for the award of the degree of
Bachelor of Engineering
In
Mechanical Engineering
Submitted by

ABHISHEK RAVINDRAN 1V117ME002

DEPARTMENT OF MECAHNICAL ENGINEERING, VEMANA INSTITUTE OF

TECHNOLOGY, BENGALURU – 560034
2020-2021
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Karnataka Reddy Jana Sangha®

VEMANA INSTITUTE OF TECHNOLOGY
(Affiliated to Visvesvaraya Technological University, Belagavi)
Koramangala, Bengaluru-560034.

DEPARTMENT OF MECAHNICAL ENGINEERING

CERTIFICATE
This is to certify that the Internship/Professional Practice work entitled
“SOLAR WATER PUMPING SYSTEMS” is a bonafide work carried out by Mr.
Abhishek Ravindran during the academic year 2020-21 in partial fulfilment of the
requirement for the award of Bachelor of Mechanical Engineering of the
Visvesvaraya Technological University, Belagavi. It is certified that all
corrections/suggestions indicated for internal assessment have been incorporated in
the report. The internship report has been approved as it satisfies the academic
requirements in respect of the Internship/ Professional Practice prescribed for the said
degree.

Guide Head of the Department Principal

(Prof. Anup T J) (Dr. Lokesh G Reddy) (Dr. Vijayasimha Reddy B.G)

External Viva

Name of the Examiner Signature with date

1.

2.
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ACKNOWLEDGEMENT
I sincerely thank Visvesvaraya Technology University for providing a
platform to do the internship work.
I express my sincere thanks to Dr. Vijayasimha Reddy B G, Principal,
Vemana Institute of Technology, Bengaluru, for providing necessary facilities
and motivation to carry out internship work successfully.

I express heartfelt gratitude and humble thanks to Dr. Lokesh G Reddy, HoD,
ME, Vemana Institute of Technology, for his constant encouragement,
inspiration and help to carry out internship work successfully.

I am very thankful to my external guide, Shanthi G, Consulting Faculty (Solar)

, at Company name who has given in-time valuable instructions and put me in
contact with experts in the field, with extensive guidance regarding practical
issues.

I would like to express my sincere gratitude towards my internal guide

Prof Anup T J, Assistant Professor for providing encouragement and
inspiration throughout the internship.

I thank Mr. Naveen Kumar R, Assistant Professor, the internship coordinator

for his boundless cooperation and support during the internship work.

I thank Prof. Aswathappa C M, for his constant encouragement, inspiration

and help to carry out internship work successfully.

I am thankful to all the teaching and non-teaching staff members of Mechanical

Engineering Department for their help and much needed support throughout
the internship.
ABHISHEK RAVINDRAN
1VI17ME002
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ABSTRACT

Solar energy is considered a renewable and environmentally friendly energy

source. The photo voltaic technology is the most popular technology that
directly utilizes solar energy and converts it to Direct Current (DC). One of the
most popular applications of PV power systems is the Photovoltaic Water
Pumping Systems. Farm machinery, farm building and production facilities are
constantly being improved under the solar sector. This report is a compilation
of my 3 weeks internship experience on solar water pumping systems at
Mahatma Gandhi Institute of Rural Energy Development (M.G.I.R.E.D). My
responsibilities included understanding the basics of solar energy from scratch,
and major components required for the construction and working of a
standalone water pumping system. Rather than only having theoretical
knowledge this internship also provided hands on experience on testing and
commissioning of a standalone solar water pumping system along with the
required prerequisites.
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TABLE OF CONTENTS
CHAPTER TITLE PAGE

Acknowledgement 4
Abstract 5
Table of Contents 6
List of Figures 7
List of Tables 8
1 INTRODUCTION 9
1.1 What is solar water pumping system 9
1.2 Components of Solar Water Pumping System 9-13
1.3 Types of Water Pumping System 13-14
2 ORGANIZATION OVERVIEW 15
2.1 Vision of M.G.I.R.E.D 15
2.2 Mission of M.G.I.R.E.D 15-16
2.3 Objectives of M.G.I.R.E.D 16-17
2.4 Departments of M.G.I.R.E.D 17-18
2.5 Organization Chart 19
2.6 Associate Organizations of M.G.I.R.E.D 19-20
3 VARUNMITRA SKILL DEVELOPMENT PROGRAM 20
3.1 Aim of Internship 20-21
3.2 About Varunmitra Skill Development Program 21
3.3 Tasks performed during the course of internship 22

3.3.1 Week 1 23-34

34-39
3.3.2 Week 2
40-45
3.3.3 Week 3
4 CONCLUSIONS 46
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LIST OF FIGURES
FIGURE PAGE
TITLE
NO. NO.
1.1 A Typical Solar Water Pumping System 10
1.2 Seasonal Changes in Array Tilt Angle to Maximize Pump Output 11
1.3 Typical installation of centrifugal pump unit drawing water 12
1.4 Typical solar powered positive displacement pump unit 12
2.1 M.G.I.R.E.D 15
2.2 M.G.I.R.E.D Organization Chart 19
3.1 Solar cell, Module and Array 24
3.2 Solar Water Pumping System 25
3.3 Solar panel 26
3.4 Pump 26
3.5 Solar battery 27
3.6 Solar inverters 28
3.7 Charge controller 28
3.8 Submersible pump 29
3.9 Surface pump 30
3.10 Types of Motors 31
Demonstration of I-V and PV characteristics for polycrystalline panels
3.11 32
and combination of mono and poly crystalline panels
3.12 Results for I-V and PV characteristics 32
3.13 Tilt angle experiment and result 33
3.14 Shading experiment and result 34
3.15 PV SOL Interface 34
3.16 Installing Module Mounting Structure 37
3.17 Single Line Diagrams 38
3.18 Checking Resistance of Earthing 39
3.19 Remote Monitoring System 39
3.20 B.O.M for P.V pumping System 41
3.21 Final Day Assessment 45
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LIST OF TABLES

TABLE NO. TITLE PAGE NO.

3.1 Weekly tasks 22
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Chapter-1

INTRODUCTION

1.1 What is a solar water pumping system?

Pumping water is a sensible and effective use of solar electric power. During the hot
months, when water requirements are highest, a solar pump will provide a reliable water
source for the farm. Wind power, by comparison, can be inconsistent, and may not be
available during the hottest months in many inland areas. Wind may be too unreliable for
water pumping when a relatively constant supply is required, as for stock watering. A solar
water pumping system is essentially an electrically driven pumping system. Electricity, in
this instance, is produced by the sunlight energizing photovoltaic (solar) modules.
The typical solar cell is a thin wafer of silicon that transforms light energy into electrical
energy. The cells are encapsulated in flat modules to protect them from the weather. Any
number of modules can be connected together to form an array. The array is sized to meet
a pumping systems’ power requirements. A solar pumping system is available for almost
all applications where an electric pump can be used. Because solar energy varies from one
location to another, and over the course of a day, system design is important.
Adequate water storage ensures that water is available whenever needed, and balances daily
variations in water supply and demand. Thus, a small pump only running when the sun
shines, plus water storage, can provide the average requirement for water supply. For the
best electrical and mechanical performance, all components of the solar pumping system
must be carefully matched. Correct sizing of the pump, motor and controlling devices, will
allow the system to operate at the highest efficiency to ensure economical
water pumping.

1.2 Components of solar pumping systems

Although solar water pumps have been developed from some fairly sophisticated “hi-tech”
components, they are relatively simple, uncomplicated packages of equipment.
Solar water pumping systems consist of three basic components:
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1. Power source (photovoltaic solar modules)

2. Motor/pump (or motor/compressor) assembly
3. Power controllers for matching the changing electrical output of the array to suit
the motor/pump

Fig 1.1 A Typical Solar Water Pumping System

1. Power source
Each solar cell produces about 0.5 volts in bright sunlight. Solar cells are linked together
in a series to form a module and to produce the required voltage. Solar modules are linked
together in a series and in parallel to provide the power levels needed for the required
application. Typical system voltages are 12 volt and 24 volt, 48 volt, 110 volt and 180 volt
DC. The linked modules, called an array are usually fixed to a light aluminium structure
and can be mounted on the ground, on a roof or on a trailer. In Australia, an array should
face ‘true’ North. The tilt angle is set to suit the season and the latitude of the pump’s
location. As the sun varies with the season, the angle of the solar array may be further
adjusted to achieve maximum output, although the gains produced by this method are small.

Sunlight levels vary with latitude and a larger solar array would generally be required the
further south the location. Extra performance, possibly up to 30% can be achieved by
turning the solar array to track the movement of the sun throughout the day. These ‘sun
trackers’ are automatic mechanisms that add complexity and extra cost to the system.
However on larger systems tracking the sun can significantly reduce the cost of delivered
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water. Photovoltaic cells convert sunlight into direct current (DC) electricity. Some solar
water pumping systems use DC motors, whilst others use AC motors (alternating current)
and incorporate an inverter.

Fig 1.2 Seasonal Changes in array tilt angle to maximize pump output

2. Motor/pump assembly
Off–the–shelf, mass produced motors and pumps can be used for solar water pumping.
Special pumps and motor have also been developed for solar systems. The power from a
solar system and the volume of water pumped varies with the amount of solar radiation.
This means that the system must be designed to work efficiently over a range of voltage
and current levels
(i) Electric motors
Solar water pumps that are currently available, use the following types of motors.
• AC synchronous motors
• AC asynchronous induction motors
• DC series motors
• DC permanent magnet motors
• DC permanent magnet brushless motors
The permanent magnet DC motor achieves higher efficiencies, whilst the use of an AC
motor in a solar pump requires an inverter.

(ii) Pumps
Centrifugal pumps
Centrifugal pumps are designed for a fixed head and their water output increases with
rotational speed. Centrifugal pumps are not self–priming and are seldom used for suction
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lifts greater than 4-5m. solar powered floating pumps are often of this type, at low heads,
centrifugal pumps are usually more efficient than positive displacement pumps.

Fig 1.3 Typical installation of centrifugal pump unit drawing water

Positive Displacement Pumps

Positive displacements pumps have a water output which is directly proportional to speed.
Helical shaped rotor pumps have very few moving parts, operate at low speeds and are able
to handle dirty water. The flow is non pulsating and ideal for long distance pumping. The
efficiency of the pump increases with head and consequently at higher heads, positive
displacement pumps can be more efficient than centrifugal pumps.

Fig 1.4 Typical solar powered positive displacement pump unit

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3. Power Controllers
There are several types of power controllers available:
• Impedance matching devices (such as power maximisers)
• DC to AC inverters (used with AC pumps only)
• Switches and protective controllers.
Impedance matching devices such as power maximisers, sometimes called maximum
power point trackers (MPPT’s), control the output of the array so it will operate close to its
maximum efficiency (power) over a range of sunlight levels.

1.3 Types of water pumping systems

Water pumping systems are classified depending on the type of pump used (AC or DC) and
the configuration of the systems. There are two configurations of water pumping systems:
standalone systems and hybrid systems. Hybrid systems in general use two energy sources
such as a wind turbine, diesel generator, or PV. The AC standalone water pumping systems
in general consist of a PV array, an inverter with a centralized maximum power point
tracker, and a pump. Such a system can have a block of batteries as a backup power supply,
but because the system cost is a very important factor, systems are designed in a way to
meet the village demand during the solar day without any need for batteries.

There are two broad categories of pumps used in standalone PV systems around the world:
rotating and positive displacement. There are many variations on the designs of these two
basic types. Examples of the rotating pump type are centrifugal, rotating vane, or screw
drive. These pumps move water continuously when power is presented to the pump. The
output of these pumps is dependent on head, solar radiation (current produced), and
operating voltage. They are well suited for pumping from shallow reservoirs or cisterns.
They can be tied directly to the PV array output, but their performance will be improved
by using an electronic controller such as a linear current booster to improve the match
between the pump and the PV array. Positive displacement pumps move “packets of water.”
Examples are diaphragm pumps and piston pumps (jack pumps). These pumps are typically
used for pumping water from deep wells. Their output is nearly independent of the pumping
head and proportional to solar radiation. Jack pumps should not be connected directly to a
PV array output because of the large load current changes during each pump cycle.
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In general, peak power controllers are recommended. The controllers adjust the operating
point of the PV array to provide maximum current for motor starting and then keep the
array operating at the maximum power conditions. In some cases, designers use batteries
between the jack pump and the array to provide a stable voltage source to start and operate
the pump.
Usually they are not sized to provide night-time pumping, but only to give stable system
operation. Pumps are also categorized as surface or submersible. Surface pumps have the
obvious advantage of being more accessible for maintenance. When specifying a surface
pump, you must distinguish between suction and lift. A pump may be installed a few feet
above the water level, with a pipe from the pump to the water. The maximum length of the
pipe is determined by the suction capability of the pump.
The pump may then “lift” the water to a storage tank above the pump. The elevation of the
storage tank is determined by the lift capability of the pump. Most submersible pumps have
high lift capability. They are sensitive to dirt sand in the water and should not be run if the
water level drops below the pump. The type of pump depends on the water required, the
total dynamic head, and the capability of the water source.
Meanwhile, both rotating and displacement pumps can be driven by AC and DC motors.
The choice of motor depends on the water volume needed, the efficiency, the price, the
reliability, and the availability of support. DC motors are an attractive option because of
their compatibility with the power source and because their efficiency is usually higher than
that of AC motors. However, their initial cost is higher, the selection may be limited in
some countries, and the brush-type motor requires periodic maintenance. Some brushless
DC motors are available and promise improved reliability and decreased maintenance. AC
motors require a DC-to-AC inverter, but their lower price and wider availability are
advantages.
In water pumping systems, storage can be achieved by using batteries or by storing the
water in tanks. Adding batteries to a system increases the cost and decreases reliability.
Water storage is better for most applications. However, considerable evaporation losses can
occur if the water is stored in open tanks or reservoirs. Meanwhile, closed tanks large
enough to store several days of water supply can be expensive. In some countries, these
tanks are not available or the equipment necessary to handle, move, and install the tanks
may not be available. Also, any water storage is susceptible to vandalism and pollution.
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Chapter-2
ORGANIZATION PROFILE

MAHATMA GANDHI INSTITUTE OF RURAL ENERGY DEVELOPMENT

Fig 2.1 M.G.I.R.E.D

Mahatma Gandhi Institute of Rural Energy and Development (MGIRED) located in
Bengaluru was established in the year 2000 with assistance of Ministry of New and
Renewable Energy (MNRE), Government of India and the Rural Development &
Panchayat Raj Dept., Government of Karnataka. The main objective was to have a unique
Institution to carry out Capacity Building and Awareness Programmes in the areas of Rural
Energy and Sustainable Rural Development which will cater to the needs of Karnataka and
neighbouring southern states namely Andhra Pradesh, Telangana, Tamil Nadu, Kerala and
Union Territory Pondicherry.

2.1 Vision of M.G.I.R.E.D

To be a lead knowledge & Resource Center of Excellence in Renewable Energy, Energy
Conservation, Natural Resource Management, Environmental Protection, Forestry, Rural
Development and allied subjects.

2.2 Mission of M.G.I.R.E.D

An institute built on principles of intellectual excellence, we are committed to deliver high-
quality competitive Education, Research, Demonstrations, Evaluation, Policy advisory.
Institute strives to establish unique identity for the development of human and knowledge
reserve by developing and implementing state-of-the art training programmes founded on
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high academic standards, public engagement and productive partnerships with leading
institutions in the world.

2.3 OBJECTIVES OF M.G.I.R.E.D

• Develop and implement state-of-the art programmes in partnership with state and
national stakeholders through best practices for Renewable Energy, Energy
Conservation, Environment and related subjects.

• Reform training and extension systems which will enhance human resource quality.
Preparing individuals who will have passion for professional excellence and
proactively engaged in betterment of society.

• Create an environment for making teaching more learner centric rather than
academic.

• Improve knowledge management system to act as an efficient Technology Backup

Unit for RDPR for providing information on Renewable Energy, Environment,
Sustainable Development, Natural Resources Conservation and Allied Sectors.

• Promote a centre of learning that will fully support the rapid development of the
Rural Energy, Energy Conservation, Natural Resource Conservation, Sustainable
Development, Environment sectors.

• To ultimately upgrade to a degree awarding institution providing

alternative/vocational degree programmes for persons willing to enhance career
opportunities.

• Establish a database on Rural Energy demand and supply for different micro-
regions of the state and sub-regions.

• Establish demonstration centers for various technologies appropriate for rural areas.

• Carry out Research and Development on Renewable Energy Applications and

Energy Conservation Opportunities in Rural Environment, Forestry, Rural
Entrepreneurship, Waste Recycling, etc.

• Perform functions, incidental or ancillary in line to the above subjects.

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• Carryout evaluation of RDPR programmes and give feedback to help improve the
effectiveness of the programmes.

2.4 Departments of M.G.I.R.E.D

1. Department of Solar Technology

2. Department of Small Wind and Pico Hydel Energy
3. Department of Environment Science
4. Department of Bio-Energy
5. Department of Rural Development
6. Energy Conservation and Management

2.4.1 Department of Solar Technology

Areas of research:

• Roof Top Photovoltaic Systems operating in Islanded mode and Grid connected
mode (net metered).
• Solar Photo Voltaic Water Pumping Applications.
• Remote Village Electrification using micro grids / nanogrids.
• Solar based Hybrid Systems for power generation.
• Evaluation of Solar PV cell technologies used in power generation.
• Solar Thermal Applications viz. Water heating Systems, Dryers.
• Solar based Applications for Rural Environment.
• Field studies on installed Solar Energy System

2.4.2 Department of Small Wind and Pico Hydel Energy

Areas of Research:

• Pico Hydro Power Generation from Sewage Water

• Pico Hydro Power Generation from Canal Water
• Portable Small Wind and Solar Hybrid System
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2.4.3. Department of Environmental science

Areas of Research:

• Biofertilizers and Biopesticides

• Biodiversity Studies
• Environmental Policy Analysis
• Urban Pollution Analysis
• Rainfall Anomalies and Climate Change

2.4.4. Department of Bio Energy

Areas of Research:

• Bio-fuels
• Biogas
• Microbial Hydrogen Production

2.4.5 Department of Rural Development

Areas of Research:

• Rural sanitation
• Health and Nutrition
• Women entrepreneurships

2.4.6 Energy Conservation and Management

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2.5 Organization Chart:

Fig 2.2 M.G.I.R.E.D Organization Chart

2.6 Associate Organizations of M.G.I.R.E.D

Mahatma Gandhi Institute of Rural Energy and Development is Associated with the
following Institutions / Organizations:

• Ministry of New & Renewable Energy, Govt of India (MNRE)

• Ministry of Rural Development, Govt of India (MoRD)

• Ministry of Environment & Forest, Govt of India (MoEF)

• Petroleum Conservation Research Association, Govt of India (PCRA)

• Rural Development & Panchayat Raj Department, Govt. of Karnataka (RDPR)

• Karnataka Forest Department Govt of Karnataka (KFD)

• Central Power Research Institute, (CPRI)

• Indian Institute of Science (IISc)

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• University of Agricultural Sciences (GKVK)

• Karnataka State Council for Science & Technology (KSCST)

• Karnataka Renewable Energy Development Ltd (KREDL)

• Karnataka Power Transmission Corporation Ltd (KPTCL)

• Karnataka State Road Transport Corporation (KSRTC)

• The Energy and Resources Institute (TERI)

• Technology Innovation Design Endeavour (TIDE)

• Malavalli Power Plant Ltd, (MPPL)

• Pollution Control Board, Govt.of. Karnataka

• SELCO

Chapter-3

VARUNMITRA SKILL DEVELOPMENT PROGRAMME (INTERNSHIP)

3.1 Aim of Internship:

The ‘Solar Photovoltaic Water Pumping Systems’ is one of the most useful and popular
application of Solar Energy for meeting the irrigation needs. Govt. of India is formulating
many schemes to support the Solar Water Pumps for the farmers. It aims to incentivize
farmers to run solar farm water pumps and use barren land for generating solar power to
have extra income.

Installation of such a large number of ‘Solar Pumps’ would necessarily need ‘Trained and
Skilled’ manpower for installation/ commissioning as well as for repair/ maintenance. To
fulfil this need, NISE is organizing a specialised ‘Training Programs on Solar Water
Pumping Systems’ on ‘PAN India’ basis to impart the knowledge and guidance in design,
installation, commissioning, safety, and operation & maintenance of the solar water
pumping systems. The aim is to create a ‘Pool of Trained and Skilled Workforce’, who will
be called as ‘VARUNMITRAS’.
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In the past NISE has conducted twenty-six similar programs on Solar Water Pumping
systems (Called as Varun Mitra Programme) which have been appreciated and the demands
have been invited for organizing further trainings. The participants in these ‘Training
Programs’ were from different States (Rajasthan, Uttar Pradesh, Assam, Delhi, Haryana,
Madhya Pradesh, Mizoram, Punjab, Tamil Nadu, Maharashtra Bihar/ Jharkhand, Andhra
Pradesh/ Telangana and Gujarat).

The Ministry of New & Renewable Energy, Government of India, vide letter no. 32-
11/2/2018-HRD dated 25.05.2018 sanctioned NISE to conduct the Solar Water Pumping
Program across the country. The goal of this training Program is to create trained manpower
for the installation, operation, and maintenance of the Solar Water Pumping Systems. In
this regard, NISE launched a 21-days / 120 hrs Solar Water Pumping Programme titled
‘Varunmitra’ to impart comprehensive training to about 400 participants.as per the proposal
of, NISE organized these training programs through the government institutes.

3.2 About Varunmitra Skill Development Program

VSDP aims to develop the skills of youth, considering the opportunities for employment in
the growing Solar Water Pumping Project’s installation, operation & maintenance in India
and abroad. The VSDP is also designed to prepare the candidates to become new
entrepreneurs in Solar Water Pumping sector. This is 3 weeks/ 21 days / 120 Hrs. residential
skill development program following the Qualification Pack of Skill Council Green Jobs
[SCG/Q0112 (SGJ/N0134)].

Target Participants: The target participants are Solar Entrepreneurs, Public Sector
Undertaking officials, EPC Contractors, State Nodal Officers (SNA), manufactures etc.

Qualification: As per qualification of SCG/Q0112 (SGJ/N0134), the candidates should

have Diploma and Degree in Electrical/Electronics/Civil/Mechanical.

Number of Participants: 30 Participants in a batch.

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3.3 Tasks Performed During the Course of Internship

WEEK 1 WEEK 2 WEEK 3

Solar Energy Designing of solar water Understanding of
Fundamentals pumping systems B.O.S Components
Introduction to solar Solar Water Pump

water pumping systems Design aspect site

Bill of Materials

Components of solar Mounting Structures – Testing and commission

water pumping system of solar pumps
Design and Drawing

Foundation

Types of pumps Inverters- Types and Business Aspects of Solar

Basic Terminologies Water Pumping System

Fundamentals of Single Line Diagrams Brief Review on KUSUM

(SLD) Scheme by Govt. in Solar
Different types of Motors
Sector

Effect of temperature, Concept of Earthing Assessment and

Area , Tilt and Shading Certification
selection of solar PV
Module
Demonstration of I-V and Remote monitoring
PV Characteristics With system
series and parallel
combination

Table 3.1 Weekly Tasks

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3.3.1 Week 1

Theoretical implementation:

Theoretical knowledge is very important in which the trainee will learn the basics about
solar energy and its benefits of solar energy and what is solar water pumping systems. Why
it is the most trending course and what are the advantages of doing this internship, acquire
basic skills and get an better insight on solar water pumping systems before implementing
it practically.

➢ Solar Energy Fundamentals

The first class of the internship was about the orientation, which led to the discussion
about the fundamentals of solar energy

Solar energy is a major renewable energy source with the potential to meet several
challenges we face as humankind. This power source is increasing in popularity because of
its versatility and many benefits to people and the environment. Climate change has led to
real crisis, with increase in flooding and hurricanes due to disturbed weather patterns. High
carbon dioxide content in the atmosphere is making oceans acidic and killing marine life.
Higher temperatures lead to melting of polar ice caps, reducing habitats for wildlife and
increasing sea level. Irregular rainfall or increasing droughts affect agriculture and
livelihoods of the weaker sections of society all around the world.

Photovoltaics (often abbreviated as PV) are simple devices that provide us with an elegant
method of harnessing the sun’s energy. PV devices (solar cells) can directly convert the
incident solar radiation into electricity. They produce no noise, produce no pollution, and
do not include moving parts. Hence, they are robust, reliable and long lasting.
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Fig 3.1 Solar Cell, Module and Array

The primary component of a solar cell is silicon. Silicon is a semiconductor material at its
core, and actually a very poor conductor of electricity. In 1839, Edmund Becquerel
discovered that electrical energy could be harnessed from the sun during certain
electrochemical configurations. Silicon is suitably doped with certain impurities to employ
a solar photovoltaic (PV) cell to capture energy from the sun and convert it into electricity.

In the operation of solar cells, the principle is that when a photon reaches a semiconductor,
it ejects an electron leading to the creation of two conductors: the free electron and the
electron hole. When the PN junction is exposed to light, photons with energy greater than
the bandgap of silicon cells are absorbed, causing the emergence of electron-hole pairs.
These carriers are separated under the influence of electric fields within the junction,
creating a current that is proportional to the incidence of solar irradiation.

➢ Introduction to solar water pumping system

A solar energy-powered water pump is a water pump running on the electricity that is
generated by solar photovoltaic modules. Solar photovoltaic (PV) systems can be an
attractive complementary energy source deployed alongside diesel pumps in areas with
plenty of sunshine and where the cost to run power lines is high. Photovoltaic systems have
the benefit of being scalable, with capacity ranging from a few watts for applications such
as automated farm gates or timers, to hundreds of kilowatts for the homestead and farm
 25

sheds. Rather than having one large centralized system, a number of distributed PV systems
can be deployed at pump sites.

Solar pumping systems are best suited for transfer operations (to pump water out of bore,
for instance, or transfer it from dam to storage tank) in which pumps run continuously for
most of the day. Applications that require water to be pumped at night are not as well suited
for solar powered pumps, as storage solutions such as batteries and storage tanks can add
significantly to the cost of the system. Although these energy storage solutions can be
expensive, they allow for greater utilization of the PV system. Depending on the
application, stocked water can be fed by gravity when there is insufficient sunlight to power
the sola pumps, thus reducing diesel consumption further. Due to the high capital costs that
are still associated with solar systems, simple paybacks of seven to eight years are generally
achievable only where pumping currently occurs for more than half the year. These costs
are expected to reduce over the coming years as price reductions occur within the solar PV
and commercial battery storage industries.

Fig 3.2 solar water pumping system

➢ Components of solar water pumping systems

The major components of solar water pumping systems are:

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• Solar panels

A solar panel is the main component of the solar water pumping system. A group of solar
panels is known as an Array. A solar panel creates electricity by allowing photons, light
rays to knock electrons free from and hence generate electricity. A solar panel comprises
of other smaller units known as photovoltaic cells which convert sunlight to electricity.
There exist different types of solar power technology, such as solar thermal and
concentrated solar power.

Fig 3.3 solar panel

• Water pumps
The water pump is another part of the solar water pump system that is extremely important.
Without the pump, you wouldn’t have a water pump system! The pump is the piece of
equipment that draws water from the source to be used for different applications. Water can
be drawn from a well, pond, or other sources and used to help with agriculture, irrigation,
and other settings. Advanced Power offers our pumps in both AC and DC power. You can
find submersible pumps, circulation pumps, booster pumps, and sump pumps in our
collection of solar water pumps. Submersible pumps can lift water from great depths. We
can help you find the right water pump for your needs and application.

Fig 3.4 Pump

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• Solar batteries

Batteries store the charge generated by the solar panels. During the day, electricity
generated by the solar panels is supplied to the battery and the load. When the load demand
is higher than the energy received from the solar panels, these batteries will provide stable
power to the pumping systems. Batteries ensure that the water pumping systems run
whether the sun shines or not.

Fig 3.5 solar battery

• Solar Inverters

Inverters convert direct currents (DC) to Alternating Current (AC). The conversion of DC
to AC is necessary for several electrical devices, including the Water pumps. Consequently,
this makes an inverter an essential component of the water solar pumping system. However,
the use of DC pumps eliminates the requirement of inverters. During cloudy and low light
days, the inverter is a high power back up keeping your water pumps running even without
solar.

If you are considering investing in solar water pumping systems, the knowledge about these
components gives you a clear picture of what you are investing in and their benefits versus
the cost.
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Fig 3.6 Solar Inverters

• Controllers

Controllers work as a powerful component to increase the performance and keep complete
control over the water pump. It can be used to set a pumping schedule, turn the pump on or
off, and also help to increase its life span. You can opt for controllers that come with water
sensors when pumping water from water sources that often endures low water levels or dry
conditions. These can help to maximize the performance and efficiency of your pumps even
more.It is good to approach a solar pump controller manufacturer to get the equipment you
need to meet your precise needs.

Fig 3.7 Charge controller

➢ Types of pumps

The solar-pumps are classified into four types namely

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• submersible solar pumps,

• surface solar-pumps,
• DC pumps, and
• AC pumps.

• Submersible solar Pumps

These pumps can lift the water up to 650 feet and fit within a big well. Whenever the water
deepness in the well is above 20 feet from the surface then these pumps can work straightly
turn off batteries, solar panels, otherwise power source in some cases. Generally, water is
pumped throughout the day as the sun is shining & the water is stored in a tank for utilize
whenever required. It is suggested to store the water only in a good weather condition
because if the weather is not good then the water will not pump. These types of pumps
mainly used in places wherever water is accessible at a larger depth & wherever open wells
do not exist. The highest suggested depth for pumping is 50 meters.

Fig 3.8 Submersible Pump

• Surface solar pump

These pumps are used in ponds, shallow wells, storage tanks otherwise streams. If the
deepness of the water supply in the well is 20 feet or less than 20 feet from the surface.
Generally, these pumps can’t pick up the water very high from the deep well, they can push
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the water 200 feet or above distance. These pumps are apt for pumping as well as lifting
water from the highest deepness of 20-meters.

Fig 3.9 Surface pump

• DC Solar pump

The motor used in this kind of pump works with direct current, thus there is no need for
inverter or battery.

• AC Solar Pump

The motor used in this kind of pump works with AC, which means the DC generated by
the panels gets changed to AC with the help of an inverter. This conversion leads to power
failure from production & utilization.

➢ Fundamentals of Different types of motors

An electric motor (or electrical motor) is an electric machine that converts electrical energy
into mechanical energy. Most electric motors operate through the interaction between the
motor’s magnetic field and electric current in a wire winding. This interaction generates a
force (as per Faraday’s Law) in the form of torque which is applied to the motor’s shaft.
 31

Electric motors can be powered by direct current (DC) sources, such as batteries or
rectifiers. Or by alternating current (AC) sources, such as inverters, electric generators, or
a power grid.

Fig 3.10 Types of Motors

Practical Implementation:

Practical work is a very important aspect in a skill development process because the skill
is enhanced only if the knowledge that the trainee has gained is implemented practically,
as practical exposure helps the trainee to understand his strength and flaws, and helps the
trainee to improve and upgrade his skills. The trainee gets a better insight about the solar
components used in the solar water pumping systems.
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➢ Demonstration of I-V and PV characteristics

Solar cell I-V and PV characteristics curves show the current and voltage characteristics of
a particular photovoltaic cell, module or array giving detailed description of its solar energy
conversion ability and efficiency. Knowing the electrical I-V characteristics of a solar panel
is critical in determining the device’s output performance and solar efficiency.

Fig 3.11 demonstration of I-V and PV characteristics for polycrystalline panels and
combination of mono and poly crystalline panels

Fig 3.12 Result for I-V and PV characteristics

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➢ Effect of tilt and shading selection of PV module

• Effect of tilt

The array’s tilt is the angle in degrees from horizontal. A flat roof has a 0-degree tilt and a
vertical wall mount has a 90-degree tilt angle. Whether you are installing a solar panel on
a flat roof or a pitched roof, the output of the solar PV system would be increased by
optimizing the tilt angle.

Fig 3.13 Tilt angle and result

• Shading of PV Module

Solar PV systems comprise of a number of solar panels wired into arrays depending on the
electric power demand from each of those panels, which in turn, composed of many solar
PV cells that are the essential units involved in capturing energy from the sun and
converting them into electricity. Now, if a shadow falls even only on one part of the solar
panel in your array, the output from the complete system may be potentially compromised,
this can be referred to as shading of PV panels.
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Fig 3.14 shading experiment and result

➢ 3.3.2 Week 2
• Designing of solar water pumping systems using PV SOL/ PV SYST

Solar PV technology is one of the most important resources of renewable energy. Hence
there is a need to develop software tools which is able to determine the potential energy
characteristics and operating performance of PV system. The main objective was to
understand an off- grid system, on- grid system and hybrid system and design a solar power
plant with the help of simulation software. Which typically includes major designing
aspects such as orientation of modules, solar components, user needs, near and far shading
analysis, etc.,

Fig 3.15 PV SOL Interface

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• Solar water pump design aspect

Typical design of solar water pump system

Different regions and customers have different demands, so different designs must be
carried out for different demands. Therefore, the premise of the design is to give the
customer the most optimized solution based on fully understanding the customer's needs,
so as to meet the users’ demand needs to the greatest extent.

1. Model selection procedure

Confirm the head and flow of water pump

The head is the vertical distance from the pump water inlet to the outlet, and the flow is the
daily water consumption. Confirm the power of the water pump It depends on the head,
flow and outlet diameter and so on. Confirm the inverterThe power of the inverter is 1.1-
1.3 times of the water pump motor power.Confirm solar panel capacity The power of solar
panels is 1.3-1.5 times of the inverter power. Selection of the cable specification It depends
on the connection distance between the inverter and water pump

2. Obtain user demand - Daily water demand, head and diameter of the well

Before configuring the solar water pump system, it is required to know the customer
information in detail to give an effective solution. For instance, the information of a
customer is that we should understand before as follows:

The well depth is about 55m, the head is about 48m, and the well diameter is about 200mm.
Need to irrigate 5 hectare. The entire irrigation period requires about 27000 m3 water and
irrigates for a continuous six months. The local average sunshine is about 5 hours per day.
solar water pump system About the head of water pump, the following is a bried
introduction about it. The head refers to the height at which the pump can lift water, usually
expressed in H, and the unit is m.

Pump head = static head + horizontal delivery distance + loss head

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The static head refers to the altitude difference between the suction point of the pump and
the high control point. For example, pumping water from a deep well and sending it to a
high water tank, the static head refers to the altitude difference between the water suction
point in the well and the water tank at the high point. As shown in the figure, the static head
is H1+H3, and the horizontal delivery distance is shown in figure H2. When the head is
generally calculated, the head is counted as 1m for every 10m in the horizontal direction.
The loss head is usually 6% to 9% of the net head, such as water pipe elbow, waterhead
and so on, which is generally 1~2 m.

Now see the specific selection of the solar water pump system configuration

1. Solar water pump

According to the known head and flow, a suitable water pump can be referred in a reversed
manner: for examp, 1000 m3 water is pumped in 300 days, the local sunshine is 3.5 hours,
and the system efficiency is 0.8.

Head: 110m

Flow: 1000/（300*0.8*3.5）= 1.19 m3/h

Pump selection: pump motor power 1.5kW, flow 1.2m3/H, head 115m.

2. Solar pump inverter

Generally, it is better to select the inverter that is larger than the water pump one size in
specification. The 1.5KW water pump is equipped with 2.2KW solar pump inverter at least.

3. Solar panels

Generally, the solar panel power to be chosen is 1.3-1.5 times of the water pump power.
Here is 1.5*1.4=2.1KW. The working voltage of the solar pump inverter is 200V-360V. It
can select the 280W solar panel, 8 pieces connected in series, a total power of 2.24kW.
 37

• Mounting structures

Module Mounting Structures play a vital role in efficient working of a solar power system,
both in utility and rooftop. While most of the components of balance of system (BOS) such
as inverter, DC cables, junction boxes, transformers, etc. are readily bought from the
equipment suppliers, the workmanship of an EPC contractor is reflected mainly through
module mounting structures and wiring management.

These structures help panels to rest com-fortably, prevent from being damaged and more
importantly position them at precise tilt angle to harness maximum sun’s energy. Mounting
structures can be made for rooftops, ground mounting, carports and sun tracker solutions
which now have seen a lot of developments in terms of weight, material, adaptability and
ease of installation. There have been many technological innovations that have led to
reduced cost, faster and better installation, high durability and with enhanced output.

Fig 3.16 Installing Module Mounting Structure

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• Single line diagrams

Single line diagram is the representation of a power system using the simple symbol for
each component. The single line diagram of a power system is the network which shows
the main connections and arrangement of the system components along with their data
(such as output rating, voltage, resistance and reactance, etc.).

Fig 3.17 single line diagram

• Concept of Earthing

The process of transferring the immediate discharge of the electrical energy directly to the
earth by the help of the low resistance wire is known as the electrical earthing. The
electrical earthing is done by connecting the non-current carrying part of the equipment or
neutral of supply system to the ground.

There are 3 methods of earthing

1. Pipe Earthing
2. Plate Earthing
3. Strip Earthing
 39

3.18 Checking resistance of earthing

• Remote monitoring system

Solar-Pump-RMS is cost effective monitoring solution, which allows user to monitor all
data regarding Solar power generation, consumption, pump run time and fault analysis.
This gateway can enhance your pump-drive to monitor remotely. Interactive Web-Portal
presents historical and aggregated data, comparative analytical diagnosis and a guided root-
cause for fault analysis. All data are logged and can be securely reviewed and analysed at
any time from any location.

Fig 3.19 Remote Monitoring System

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➢ 3.3.3 Week 3
• B.O.S Components

A Solar PV Balance-of-System or BOS refers to the components and equipment that

move DC energy produced by solar panels through the conversion system which in turn
produces AC electricity. Most often, BOS refers to all components of a PV system other
than the modules. In addition to inverters and racking, this includes the cables/wires,
switches, enclosures, fuses, ground fault detectors, and more. BOS applies to all types of
solar applications.

BOS components include the majority of the pieces, which make up roughly 10%-50%
of solar purchasing and installation costs and account for the majority of maintenance
requirements. Essentially it is through the balance-of-system components that we: control
cost, increase efficiency, and modernize solar PV systems.

The balance of the system is, in general terms:

• The electrochemical accumulator (or batteries). In the case of some systems

isolated from the grid, the electricity generated cannot be supplied to the
grid, in these cases it must be stored in batteries or similar elements.
• The control unit.

• The current inverter, which is electronic equipment that allows modulating

and transforming the electrical current generated by the photoelectric
plates.
• Charge regulator.

• The mechanical support structure.

• The electrical wiring.

• Protection devices (fuses, earthing, and switches ).

• Bill of Materials
 41

A Bill of Materials (BOM) is a comprehensive inventory of the raw materials, assemblies,

subassemblies, parts and components, as well as the quantities of each, needed to
manufacture a product. In a nutshell, it is the complete list of all the items that are required
to build a product. A BOM is sometimes also referred to as a product structure, assembly
component list.

Fig 3.20 B.O.M for PV pumping system

• Business aspects of Solar Water Pumping System

The National Solar Mission of India is targeting 100 GW of solar energy by the year 2022,
which has fueled the demand for solar-powered resources in the country. India solar water
pumping systems market exhibited substantial growth over the past few years.

Although, the overall cost of solar water pumping systems is higher than electric and diesel
pumps, however, the government is providing up to 90% subsidy to the consumers in order
to encourage the installation of solar water pumps in the country.
 42

According to this research, the solar water pumping system market is projected to grow at
a CAGR of over 27% during 2018-2024.

Among different power ratings, 3.1 to 10 HP solar pumps segment bagged highest revenue
share in 2017 followed by up to 3 HP segment. 3.1 to 10 HP segment is projected to record
highest growth rate during the forecast period attributed to its affordability and high
subsidies provided by the government. Further, with depleting groundwater level, there is
a rising demand for submersible solar pumps and the segment is projected to grow
significantly over the coming years.

In 2017, western region contributed the highest revenue share towards overall India solar
water pumping systems market. However, the northern region is anticipated to register the
highest growth during the forecast period owing to various state government targets of solar
pumps installation in the region.

• PRADHAN MANTRI KISAN URJA SURAKSHA EVAM UTTHAAN

MAHABHIYAN (PM KUSUM) Scheme

The major objective behind the conduction of this internship program is the
PM KUSUM

• As a part of Intended Nationally Determined Contributions (INDCs), India has

committed to increase the share of installed capacity of electric power from non-fossil-
fuel sources to 40% by 2030.
• The Cabinet had approved scaling-up of solar power target from 20,000 MW of Grid
Connected Solar power Projects to 1,00,000 MW by 2022.
• While Large Scale Solar power generation projects are being installed to achieve the
ambitious target of 100 GW of Solar Power generation by 2022, it has been planned to
simultaneously develop decentralized Solar energy and other renewable energy
generation Plants of capacity up to 2 MW which could be connected directly to existing
33/11 kV or 66/11 kV or 110/11 kV sub-stations of Distribution Company, thus saving
in transmission system requirement apart from T&D losses. Such plants near these sub-
 43

stations may be developed, preferably by farmers, giving them an opportunity to

increase their income by utilising their barren and uncultivable land for solar or other
renewable energy based power plants. Cultivable land may also be used if the Solar
plants are set up on stilts where crops can be grown below the stilts and sell RE power
to DISCOMs.
• Besides, developing decentralized renewable power, it is planned to replace Agriculture
Diesel pumps with Solar Water pumps and Solarise Grid connected Agriculture pumps.
At present, over 30 million agricultural pumps are installed in India, out of which nearly
10 million pumps are diesel based. The Distribution Companies (DISCOMs) are not in
a position to energize these pumps through grid connection as seen from the long
waiting lists with such Distribution Companies. Hence there is a need to provide energy
to these pumps through solar energy. Also, over 20 million grid-connected agriculture
water pumps installed in the country consume more than 17 percent of total annual
electricity consumption of the country. Solarization of the same can reduce dependence
of these pumps on conventional sources of energy supplied by DISCOMs and thus
reducing their burden of subsidy on agriculture consumption of Electricity. This will
also provide additional source of income to farmers who will be in a position to sell the
surplus power to DISCOMs.
• The new Scheme has provision for the decentralised renewable energy plants, Solar
agriculture water pumps and solarisation of existing Grid connected Agriculture pumps.

Approval of the New Scheme for Farmers

The Government of India has launched New Scheme for Farmers with following
components:
i. Component-A: Setting up of 10,000 MW of Decentralized Ground/ Stilt Mounted Grid
Connected Solar or other Renewable Energy based Power Plants;

ii. Component-B: Installation of 17.50 Lakh Stand-alone Solar Agriculture Pumps; and

iii. Component-C: Solarisation of 10 Lakh Grid Connected Agriculture Pumps.

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The Component-A and Component-C will be implemented initially on pilot mode for
1000 MW capacity and one lakh grid connected agriculture pumps respectively and
Component-B will be implemented in full-fledged manner with total Central Government
support of Rs. 19,036.5 Crore.

After successful implementation of pilot project of Components A and C, the same shall
be scaled up with necessary modifications based on the learning from the pilot phase with
total Central Government support of ₹ 15,385.5 Crores.

All three components of the scheme aim to add Solar capacity of 25,750 MW by 2022 with
the total Central Financial Support of ₹ 34,422 crore.

• Assessment and Certification

The last day of internship was allocated for the final assessment in which the
interns had to take assessment in 3 stages. This exam is a government exam
and provides a certificate by the Government of India.

The three modes of assessments were:

1. Theoretical Assessment
2. Practical Assessment
3. Viva

1. Theoretical Assessment

This assessment was basically MCQ type questions in which the intern had to
answer a total of 30 questions within 30 minutes. Each questi on had 4 options
to choose from.
 45

2. Practical Assessment

In this assessment the interns were divided into groups of 4 or 5 and these
groups had to perform the practical experiments which were done during the
period of training and provide required results as per the needs of the external
examiner.

3. Viva

This assessment was an individual approach, the external examiner inquired

about Solar PV technology and related topics.

Fig 3.21 Final Day Assessment

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CHAPTER-4

CONCLUSION

During the 3 weeks NISE sponsored Internship on Solar water pumping systems at
Mahatma Gandhi Institute of Rural Development, Bangalore. Understood the various
aspects of solar energy and the concept of Solar Photovoltaic. A thorough knowledge on
solar resource assessment, types of Pumps and Motors, overview and understanding of
motor pump set was incorporated. Apart from this a complete commitment was given
towards learning other aspects related to solar water pumping systems such as different
controllers of solar water pumping system, fundamentals and designing of standalone solar
water pumping system, Testing standards and MNRE specification for PV pumping
systems, safety and practices requires in the field of solar water pumping. And lastly
acquired knowledge of Government policy and subsidy for solar water pumping system
and business aspects for Business aspects of solar water pumping systems
 47

REFERENCES

1. Photovoltaic Water Pumping Systems Concept, Design, and Methods of optimization

– Tamer Khatib

2. Solar Water Pump – Ibrahim Alkhubaizi

3. Solar Water Pumping by Victorian Solar Energy Council

4. https://mgired.kar.nic.in

5. https://nise.res.in