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Commissioning and Documentation
for proper Handover, Financing and Insurance
Frank Zimmermann, 10 October 2014
page 2
Commissioning and Documentation for proper Handover, Financing and Insurance
Summary
Content
• Introduction to ILF Group
• ILF – Renewable Energy Sector
• ILF – Selected PV References
• ILF – PV Software
• Commissioning and Testing
• System Monitoring
• Safety
• Documentation
• Financability and Insurability through Quality
Commissioning and Documentation
for proper Handover, Financing and Insurance
Introduction to ILF Group
page 3
page 4
The companies
• Established by Mr. P. Lässer in 1967,
In 1969 Mr. A. Feizlmayr joined the company „ILF“
• Leading international, independent engineering and consulting
firms (100% privately owned)
• Completely independent with no affiliation to construction companies,
suppliers or financial institutions optimized project solutions tailored
to the client’s needs
• Interdisciplinary engineering and management services for complex
industrial and infrastructure projects (“one stop shopping“)
• Striving for market leadership through quality
• Safety, occupational health and environmental compatibility are of
highest importance
ILF Innsbruck
ILF München
Commissioning and Documentation for proper Handover, Financing and Insurance
Introduction of ILF Group
Business areas
Production facilities for oil and gas
Pipeline systems
Tank farms and underground
storage facilities
Refineries and petrochemical
plants
Airports
Roads
Railway systems
Tunnels and caverns
Buildings and structures
Alpine engineering
Water supply
Wastewater treatment and
disposal
Waste treatment and disposal
Hydropower, dam and
river engineering
Thermal power plants
Sea water desalination plants
Renewable energy
Climate protection
Electric transmission and distribution
systems
Oil & Gas
Energy & Climate Protection
Water & Environment
Transport & Structures
page 5
Commissioning and Documentation for proper Handover, Financing and Insurance
Introduction of ILF Group
SPECIAL SERVICES
DESIGN AND
PLANNING
Preliminary
planning
Conceptual design
Permit application
design
Construction design
CONSULTANCY
Lenders Engineer
Due Diligence
Master plan
Feasibility study
Economic feasibility
study
PROCUREMENT
Tendering
procedure
Award of contract
Material
procurement
CONSTRUCTION
SUPERVISION
Quality surveying As-built
documentation
Construction cost tracking
START-UP
Personnel training
Operation manual
Maintenance manual
PROJECT MANAGEMENT
Integrated Consulting and Planning Expertise
• Geology and Hydrogeology
• Geotechnical engineering and
soil mechanics management
• Urban and environmental planning
and institutional strengthening
•Design of load-bearing structures
•Information management and GIS
•Automation and SCADA
•Project development
•Telecommunications
•Safety and risk
•Financial analysis
page 6
Commissioning and Documentation for proper Handover, Financing and Insurance
Introduction of ILF Group
Commissioning and Documentation
for proper Handover, Financing and Insurance
ILF – Renewable Energy Sector
page 7
Main Focus in Renewable Energy Sector
Thermal power plants
Sea water desalination plants
Renewable energy
Climate protection
Transmission and distribution
systems
Hydropower Photovoltaic CSP Waste to Energy Energy Efficiency
Energy & Climate Protection
page 8
Commissioning and Documentation for proper Handover, Financing and Insurance
Introduction of ILF Group – Renewable Energy Sector
page 9
Services
• Pre-feasibility assessment
• Feasibility studies
• Project appraisals
• Lender´s engineering
• Due diligences
• Project management
• Permit application design & land acquisition
• Planning & design
• EPC contracting
• Construction supervision
• Plant commissioning
• Acceptance tests
• Performance ratio verification
• Yield assessments
• 3D visualisations
Commissioning and Documentation for proper Handover, Financing and Insurance
Introduction of ILF Group – Renewable Energy Sector
page 10
Commissioning and Documentation for proper Handover, Financing and Insurance
Introduction of ILF Group – Renewable Energy Sector
Dipl.-Ing. MBA Frank Zimmermann
Education
1997 – 2002 Sales: Wholesale and Consumer
Sales- and Projectengineer
Export Manager, Fürth, de
2002 – 2005 Export Manager, Wuxi, cn
2005 – 2009 Managing Director, Singapore, sg
2009 - 2014 Managing, Haslach i.K., de
since 2014 Business Development Manager SE Asia
Project Engineer Photovoltaics
Bangkok, th
page 11
Commissioning and Documentation for proper Handover, Financing and Insurance
Introduction of ILF Group – Renewable Energy Sector
Certified Expert for Photovoltaic Equipment (TUV)
Design Vetting, Evaluation of Offers
technically
economically
Risk Analysis
Feasibility Studies
Yield Assessment
Construction Supervision and Commissioning
Check of PV Plants:
I-U-curve for PV modules and entire plants
IR Measurement
EL Measurement
… for planned or already existing PV Plants
… in Crystalline or Thin Film Technology
Commissioning and Documentation
for proper Handover, Financing and Insurance
ILF – Selected PV References
page 12
page 13
Selected References
• Photovoltaic Power Plant Dubai, UAE
PV power 13 MW, 33 kV grid connection
Status: built
Design Basis Report for 1 GW PV/CSP Power Plant
• Photovoltaic Power Plant Pakistan
PV power 100 MW
Owners Engineer, status: currently under construction
• Hybridization: PV-Diesel-Hybrid Power Plant
Al Yassat Island, UAE
Photovoltaics: 0,8 MW, 4 MW Diesel Generators
Owners Engineer, status: built
• Photovoltaic Power Plant El Salvador
PV power 17.8 MW, 46 kV grid connection
Status: built
Commissioning and Documentation for proper Handover, Financing and Insurance
Introduction of ILF Group – Selected PV References
Commissioning and Documentation
for proper Handover, Financing and Insurance
ILF – PV Software
page 14
Software: Helios 3D ________
• Based on a DGM, the rows of tables are placed shadow-free (reference date)
automatically in the terrain
• Based on Auto CAD Civil 3D
• Data export to PVSyst
page 15
Commissioning and Documentation for proper Handover, Financing and Insurance
Introduction of ILF Group – PV Software
Software: Meteonorm ________
• Highest accuracy
• 1,325 meteorological stations with irradioation
measurements
• 8,325 meteorological stations
• 5 geostationary satellites
page 16
Commissioning and Documentation for proper Handover, Financing and Insurance
Introduction of ILF Group – PV Software
Software: PVSyst 6.2.6
• Simulation program for yield assessments
• Determination of specific yield and PR
• Import of Helios 3D Data
• Calculation of near-shading losses
page 17
Commissioning and Documentation for proper Handover, Financing and Insurance
Introduction of ILF Group – PV Software
Software: PVSyst 6.2.6
page 18
Commissioning and Documentation for proper Handover, Financing and Insurance
Introduction of ILF Group – PV Software
Software: INSEL________
• Professional Simulation Software for experts
• Simulation of
• Solar insulation Data
• PV-modules
• Inverter batteries wind energy
• Pumping systems
• Solar thermal power stations
• … and its combination
page 19
Commissioning and Documentation for proper Handover, Financing and Insurance
Introduction of ILF Group – PV Software
Commissioning and Documentation
for proper Handover, Financing and Insurance
Commissioning,
Testing and Documentation
page 20
Commissioning through standarized System – Advantages
• „PV Plant Pass“ (PV Anlagenpass) or RAL seal-of-quality
• Advantages (PV Plant Pass):
• Installer proves installation according to good engineering practice
• Checklist, if installer did all neccessary works
• Complete documentation of the PV plant
• Insurances may provide cheaper rates
• Obtaining financing may be easier
• If problem occurs, detection of e.g. strings is easier
page 21
Commissioning and Documentation for proper Handover, Financing and Insurance
Commissioning and Testing
Commissioning through standarized System – Documentation
• „PV Plant Pass“ (PV Anlagenpass) or RAL seal-of-quality
• Documentation includes:
• Which components are used
• Which certificates have the components
• Which Warranties have the components
• Which norms have been applied during planning and installation
• How is the plant connected
• Plant was commissioned in „perfect shape“
page 22
Commissioning and Documentation for proper Handover, Financing and Insurance
Commissioning and Testing
Pass
• Summary of Plant
• Location
• Ownership
• Installer
• Commissioning-date
• Yield assessment
• Incl. seal
page 23
Commissioning and Documentation for proper Handover, Financing and Insurance
Commissioning and Testing
Components
• PV Modules: Manufacturer, electrical properties, certificates, warranties
• Inverter: Manufacturer, electrical properties, certificates, warranties
• DC Disconnector: Manufacturer, electrical properties, warranties
• Cables: Manufacturer, diameter, DC-string, DC-main, AC
• Mounting Structure: manufactuerer, certificates, type of system, static calculation
page 24
Commissioning and Documentation for proper Handover, Financing and Insurance
Commissioning and Testing
Information: Planning and Installation
• System configuration of PV plant: strings, arrays, installation
• System configuration of Installation: design, Overvoltage protection, theft protection
page 25
Commissioning and Documentation for proper Handover, Financing and Insurance
Commissioning and Testing
Test Reports
• Inspection Documents
• Inspection construction, installation, visit to plant
• Inspection document of electrical test of PV array
• Inspection document for electrical test of AC side
page 26
Commissioning and Documentation for proper Handover, Financing and Insurance
Commissioning and Testing
Test Reports (cont.)
• DC:
• Parameters: UOC @ STC, ISC @ STC
• Measurements: fuses, UOC, ISC, actual insolation
• Isolation Resistance: positive, negative
• AC:
• Inspect
• Probe
• Measure: R ISO, Earthing Resistance …
page 27
Commissioning and Documentation for proper Handover, Financing and Insurance
Commissioning and Testing
Certificates and Appendixes
• Attached documents:
• Electrical plan
• Roof-plan
• Modules: datasheet, warranty, certificates, list of S/N
• Inverter: datasheet, warranty, certificates, list of S/N
• DC switch/string box: datasheet, warranty, S/N
• Mounting system: data sheet, static
• Calculation of yield
• Technical documentation of monitoring system
page 28
Commissioning and Documentation for proper Handover, Financing and Insurance
Commissioning and Testing
Commissioning and Documentation
for proper Handover, Financing and Insurance
System Monitoring
page 29
Monitoring
• Online or remote ?
• Bluetooth, RS 485, Ethernet, etc.
• Internet, GPRS, etc.
• Solar Sensor (global and array)
• Wind Sensor
• Temperature sensor
• Datalogging:
• Internet Portal
• Local PC
page 30
Commissioning and Documentation for proper Handover, Financing and Insurance
System Monitoring
page 31
Commissioning and Documentation for proper Handover, Financing and Insurance
System Monitoring
General Monitoring Diagram for Large Power Plants
• Fiber optic rings connecting inverters and transformer stations
• Location of sensor units
• Type and specs of monitoring cables
• Monitoring devices in inverters and transformer stations
• Monitoring situation from combiner box
• Data transmission via satellite, UMTS, GSM, etc
Commissioning and Documentation
for proper Handover, Financing and Insurance
Safety
page 32
General Electrical Safety Rules
• Do not work alone
• Keep workspace clear
• Be alerted
• Be skeptical
• Be patient
• Expect the unexpected
• Never assume anything
page 33
Commissioning and Documentation for proper Handover, Financing and Insurance
Safety
Equipment Failures: Modules
• Cell Short Circuit
• Cell Open Circuit
• Interconnect Open Circuit
• Open circuit
• Short Circuit
• Glass Breakage
• Delamination
• Hot spot (Reverse-Biased)
• DC Arc Fault
• By-Pass Diode
• Encapsulant
• Bonding Path Resistance
• Reverse Current Overload
• Corrosion
• Strain Relief
• Insulation
page 34
Commissioning and Documentation for proper Handover, Financing and Insurance
Safety
Equipment Failures: Inverter
• Capacitor
• Bridge Circuit
• Insulation
• Output Overload
• DC Input Miss Wiring
• Ventilation
• Termination
• Component Short or Open Circuit
• Loss of Control Circuit
• Surge
• Harmonic
• Synchronization
• Overvoltage
• Ground Faultn
page 35
Commissioning and Documentation for proper Handover, Financing and Insurance
Safety
Equipment Failures: Inverter
• Capacitor
• Bridge Circuit
• Insulation
• Output Overload
• DC Input Miss Wiring
• Ventilation
• Termination
• Component Short or Open Circuit
• Loss of Control Circuit
• Surge
• Harmonic
• Synchronization
• Overvoltage
• Ground Faultn
page 36
Commissioning and Documentation for proper Handover, Financing and Insurance
Safety
Equipment Failures: Other
• Combiner
– Insulation
– Loss of Control Circuit
– Termination
– Undersized Bus
• Disconnecting Means
– Undersized
– Insulation
– Inadequate Withstand Current
• Overcurrent Protective Devices
– Undersized
– Inadequate Interrupting Capacity
• Connectors
– Inadequate Voltage Rating
– Lockable vs. non-lockable
– Make first break last ground pin in multi-pin connectors (plug)
page 37
Commissioning and Documentation for proper Handover, Financing and Insurance
Safety
Equipment Failures: Remedies
• Use appropriate overcurrent protective device type and rating.
• Assure that the maximum open circuit voltage does not exceed the equipment voltage rating.
• Assure that the maximum modules short circuit current does not exceed the inverter maximum input short circuit
current rating.
• Equipment are listed by a recognized testing agency according to approved test standards and labeled or
identified as listed.
page 38
Commissioning and Documentation for proper Handover, Financing and Insurance
Safety
Equipment Failures: Wiring
• Short-Circuit
• Ground-Fault Current
• Ground-Fault Voltage
• Excessive DC Open-Circuit Voltage
• Open-Circuit
• Overload
• Over Heat (i.e., ambient, solar radiation, harmonics, irradiance factor, etc.)
• Lack of, Improper or Inadequate Grounding (Equipment or System)
• Undersized Raceway
• Improper Terminations
• Improper connector
• Intermix of Dissimilar Metals (i.e., Cu and Al)
• Improper Binding Screws or Splicing Devices
• Improper Expansion Joints
• Rodents
page 39
Commissioning and Documentation for proper Handover, Financing and Insurance
Safety
Equipment Failures: Wiring Remedies
• Use Wire size suitable for the short circuit current of modules including the irradiance factor and solar exposure
de-rating effect.
• Use appropriate type and rated overcurrent protective devices.
• Include the effect of continues operation of the system and the ambient temperature.
• Coordinate terminal temperature ratings of various equipment terminals with that of wiring insulation.
• Use wiring insulation that is suitable for the exposed environments (wet, UV, corrosive, etc.).
• Assure wire stranding is compatible with wiring termination (i.e., fine strand vs. standard strand).
• Do not intermix different wiring materials (CU vs. AL).
• Provide properly sized equipment grounding that is based on circuit overcurrent protective device rating and
terminates into a fitting that is rated and sized appropriately
page 40
Commissioning and Documentation for proper Handover, Financing and Insurance
Safety
Equipment Failures: Wiring Remedies (cont.)
• Provide properly sized system grounding electrode conductor for grounded system that is based on PV source
ungrounded (energized) conductors.
• With some exceptions, provide dc GFP for PV system. The GFP must be sized based on KW rating of the system
by the manufacturer or the design engineer.
• Be aware that the GFP does not protect against electric shock hazard.
• Provide additional AC GFP when connecting to a service equipment or a feeder that has a GFP
• All PV system are required to have equipment grounding. Only a grounded system is required to have a system
grounding as well as an equipment grounding.
• Use properly sized raceway to avoid loss of insulation during installation.
• Limit the total number of bends in the raceway to no more than 360 deg.
• Adjust the wiring ampacity when more than three energized conductors are run in a raceway.
• Assure that the raceway is suitable for the environment encountered (i.e., temperature, physical strength, etc.).
page 41
Commissioning and Documentation for proper Handover, Financing and Insurance
Safety
Equipment Failures: Labels and Markings
• Due to inherent hazard of PV system and need for proper maintenance, numerous markings are required by listed
products and the electrical code.
• Labels and Markings may provide information on the components of the system, such as Module, PV system
operating condition, Identifying a component, Or a warning referring to possible shock hazard (i.e., upon activation
of GFP in a PV system or an open disconnect with both terminals still energized, etc.), Overvoltage, device ratings,
Presence of all sources, etc.
page 42
Commissioning and Documentation for proper Handover, Financing and Insurance
Safety
Rooftop
• Keep distances from roof sides (approx 1 m)
page 43
Commissioning and Documentation for proper Handover, Financing and Insurance
Safety
Rooftop
• Plan walkways in large installations
page 44
Commissioning and Documentation for proper Handover, Financing and Insurance
Safety
Commissioning and Documentation
for proper Handover, Financing and Insurance
Financability and Insurability
through Quality
page 45
Overvoltage Protection
• Direct positive flash
• Direct negative flash
• Overvoltage from grid
• Coupling of electromagnetic interference
page 46
Commissioning and Documentation for proper Handover, Financing and Insurance
Financability and Insurability through Quality
Overvoltage Protection
• Direct positive flash
• Direct negative flash
• Overvoltage from grid
• Coupling of electromagnetic interference
page 47
Commissioning and Documentation for proper Handover, Financing and Insurance
Financability and Insurability through Quality
Overvoltage protector
Static calculation
• Additional weight for rooftop
• Windload
• Snow ?
page 48
Commissioning and Documentation for proper Handover, Financing and Insurance
Financability and Insurability through Quality
Insuranceability
• Use Certified Products:
• Solar Modules
• IEC 61215: crystalline modules
• IEC 61646: Thin film modules
• IEC 61730: Safety Standards (like UL, JET)
• Inverter
• DC Switches
• Cables
• Plugs
• Full documentation, incl. Static calculation
Issue a PV Plant Pass (full set of requirements)
page 49
Commissioning and Documentation for proper Handover, Financing and Insurance
Financability and Insurability through Quality
Contact Details:
Frank Zimmermann Business Development Manager SE Asia
Project Manager Photovoltaics
ILF Consulting Engineers (Asia) Ltd.
Dr Gerhard Link Building, 12th floor
88 Krungthepkreetha Rd.
Huamark, Bangkapi, Bangkok 10240
THAILAND
www.ilf.com
mailto: frank.zimmermann@ilf.com
Commissioning and Documentation of Large PV Power Plants
Thank You !
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