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PV Plant Design
Optimization
Learning from India's 2GW Installations

www.reach-solar.com
Performance Data
• For this presentation
• Sample of 50 plants
operational for at least
one year in Gujarat
• 28 with c-Si and 22 Thin
Film

www.reach-solar.com
This is how the data
tables look like

?

www.reach-solar.com
?
CUF: What do you
expect?
www.reach-solar.com
Frequency Distribution CUF Values
16

Highest CUF

21.3%

Lowest CUF

12.2%

14

6

3

2

3

3

2
1
0

12% to 13% 13.1% to 14% 14.1% to 15% 15.1% to 16% 16.1% to 17% 17.1% to 18% 18.1% to 19% 19.1% to 20% 20.1% to 21% Above 21%

The Difference:
Absolute: 9.1% | Factor: 1.75

www.reach-solar.com
Frequency Distribution CUF Values
16
14

6
3
2

3

3

2
1
0

12% to 13% 13.1% to 14% 14.1% to 15% 15.1% to 16% 16.1% to 17% 17.1% to 18% 18.1% to 19% 19.1% to 20% 20.1% to 21% Above 21%

Top Performers vs. All Others
94.00%

6%

92.00%

60.00%

www.reach-solar.com

8%

40%
?
Is this problem specific
to India?
www.reach-solar.com
No, it is not!
“Nevertheless, the PV systems evaluable per region showed
significant deviations in their respective yields. Although located
in a similar environment, the yield variation in some regions was
up to 20 %. Assessment of the quartiles revealed 75 % of the
plants underperforming compared to the top performing
plants. Another 5 % were included in the group of outliers
due to their overall yield being too low for this study. The
significance test proves that, due to the sufficiently high number
of evaluable PV plants, the statistical results of our study reflect
the actual yields of the PV systems to a high degree.”
- Source: Survey on yield of photovoltaic plants 2012 in Germany
by Meteocontrol (Prof. Dr. Henirk te Heesen et al.
www.reach-solar.com
?
Is it because of the
panels?
www.reach-solar.com
CUF vs. Technology
9

7

Note:
There are 28 c-Si, but
only 22 Thin Film
installations in this
sample!

7

7

5

3
2
1

1

1

1

2

1

1

1

1
0

12% to 13% 13.1% to 14% 14.1% to 15% 15.1% to 16% 16.1% to 17% 17.1% to 18% 18.1% to 19% 19.1% to 20% 20.1% to 21% Above 21%

Thin Film

www.reach-solar.com

c-Si
CUF vs. Technology II

12% to 13% 13.1% to 14% 14.1% to 15% 15.1% to 16% 16.1% to 17% 17.1% to 18% 18.1% to 19% 19.1% to 20% 20.1% to 21% Above 21%

Thin Film

Bottom line:
There are very good and not so good
performing plants either with Thin Film
or c-Si!
www.reach-solar.com

c-Si
?
Is it because of the
size?
www.reach-solar.com
CUF vs. Average Installed Capacity
17.55
15.40
14.59

11.73

11.67

14.14

11.67
10.22

6.67

12% to 13% 13.1% to 14% 14.1% to 15% 15.1% to 16% 16.1% to 17% 17.1% to 18% 18.1% to 19% 19.1% to 20% 20.1% to 21% Above 21%

Average Installed Capacity

Bottom line:
Do larger / smaller plants perform better?
One thing is for sure: The sample of 50
plants is too small to give an answer.
www.reach-solar.com
?
So what can we learn
from this?
www.reach-solar.com
A Skeptical Thesis
• We do not have enough information, because
• Generation Data and CUF do not provide the
right or enough insights

www.reach-solar.com
?
Why have we done this
exercise?
www.reach-solar.com
Reasons
• #1: To understand better the limitations of CUF and
generation data
• #2: To build awareness that there might be a
problem & that there is room for improvement
• #3: Not specific to India – happens also in Germany
/ Europe so it affects the whole industry

www.reach-solar.com
CUF: What goes into the
equation…
• Units generated
• Installed Capacity
• Time (e.g. 1 year)

www.reach-solar.com

CUF

Energy Measured (kWh )
Installed Capacity(kW ) 8760 h
CUF: What goes not into
the equation…
• Ambient
Temperature
• Panel Temperature
• Irradiation at Project
Site

www.reach-solar.com

• Grid related aspects
• Availability
• Frequency
PR: A Different Approach
• Instead of asking:
What was achieved
without asking
about the frameconditions and
circumstances

www.reach-solar.com

• Ask:
What could have
been achieved
considering all the
frame conditions?
Comparison of CUF and PR for a PV System in Germany
(2012)

77.58%

81.54%

78.90%

78.63%

76.00%

75.90%

72.03%

74.42%

76.39%

19%

21%

78.32%

10%

14%

21%

19%

February

March

April

May

June

July

Performance Ratio [%]

www.reach-solar.com

3%

9%

4%
January

70.60%

4%

25%
18%

72.80%

August
CUF [%]

September

October

November December
Takeaways
• #1: Great components do not automatically lead to
high performing plants
• #2: Design has a huge impact (but not only
electrical design!)
• #3: CUF is a good tool but will not provide the
complete picture
• #4: PR is also a tool for quality management

www.reach-solar.com
DESIGN
CHALLENGES
www.reach-solar.com
Component

Capacity

Nos Installed

Plant
Capacity Lost

Chance of
Detection

1 Panel

250Wp

4000

0.025%

“0”

1 String

5kWp

200

0.5%

Not very likely

1 SCB

50kWp

20

5%

Possible

1 Inverter

500kW

2

50%

Likely

1 Transformer

1000kW

1

100%

Most likely

*1MW plant – not a real application; simplified for illustration

Design for Reliability
www.reach-solar.com
“Classical Approach”
•#1: Panels
•#2: Inverter
•#3: Temperature
www.reach-solar.com
“Classical Approach”
•#1: Panels
•#2: Inverter
•#3: Temperature Price
www.reach-solar.com
Min. Performance and Typical Performance of c-Si Panels vs. Time in Operation
(Aging Process)
100%
98%
96%
94%
92%
90%
88%
86%
84%
82%
80%

0

5

10
Min. Performance

15

20

Typical Performance

Performance of Panels
www.reach-solar.com

25
Simplified Output Power vs. Ambient Temperature
120

Standardized Output Power

100

80

60

Temperature
De-Rating

40

20

0
0

10

20

30

40

50

Ambient Temperature

Performance of Inverter
www.reach-solar.com

60

70
Is focusing on Panels
and Inverters enough?
www.reach-solar.com
Drainage & Civil Works
www.reach-solar.com
SCBs
www.reach-solar.com
Component

Capacity

Nos Installed

Plant
Capacity Lost

Chance of
Detection

1 Panel

250Wp

4000

0.025%

“0”

1 String

5kWp

200

0.5%

Not very likely

1 SCB

50kWp

20

5%

Possible

1 Inverter

500kW

2

50%

Likely

1 Transformer

1000kW

1

100%

Most likely

*1MW plant – not a real application; simplified for illustration

SCB: Mission Critical Component
www.reach-solar.com
Transformer Monitoring
www.reach-solar.com
…also at Plant
Level?
www.reach-solar.com
Component

Capacity

Nos Installed

Plant
Capacity Lost

Chance of
Detection

1 Panel

250Wp

4000

0.025%

“0”

1 String

5kWp

200

0.5%

Not very likely

1 SCB

50kWp

20

5%

Possible

1 Inverter

500kW

2

50%

Likely

1 Transformer

1000kW

1

100%

Most likely

*1MW plant – not a real application; simplified for illustration

Transformer: Mission Critical
Component
www.reach-solar.com
Mounting Structures
www.reach-solar.com
Mounting Structures
www.reach-solar.com
Component

Capacity

Nos Installed

Plant
Capacity Lost

Chance of
Detection

1 Panel

250Wp

4000

0.025%

“0”

1 String

5kWp

200

Not very likely

1 SCB

50kWp

20

0.5%
5%

1 Inverter

500kW

2

50%

Likely

1 Transformer

1000kW

1

100%

Most likely

Possible

*1MW plant – not a real application; simplified for illustration

Mounting Structures: Mission Critical
Component
www.reach-solar.com
No, it is not specific to India!
www.reach-solar.com
Mounting Structures
www.reach-solar.com
Conclusion
• Plant Efficiency
• EPCs and Owners Engineers – educate your clients about
plant efficiency (PR vs. CUF)

• Quality Control
• Install and use a SCADA system to monitor and document
the plant performance

• System Deployment
• Deploy a system – focus on all design aspects (not only
electrical, but also civil)

• Share
• Share your generation and performance data to set a
benchmark
www.reach-solar.com
Top Performing
Plants Now

80 / 20
Top Performing
Plants in Future
www.reach-solar.com
Contact Us
REACH Solar Consulting P Ltd.
S3 Team Business Center
98 V M Street, Mylapore
Chennai 600004
India

c/o CHROSIS UG
Hallerstrasse, 27
74549 Wolpertshausen
Germany

madhavan@reach-solar.com

sebastian@reach-solar.com

www.reach-solar.com

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REACH Solar Consultants - Presentation at Intersolar India 2013 | Learnings from India's 2GW Installations

  • 1. PV Plant Design Optimization Learning from India's 2GW Installations www.reach-solar.com
  • 2. Performance Data • For this presentation • Sample of 50 plants operational for at least one year in Gujarat • 28 with c-Si and 22 Thin Film www.reach-solar.com
  • 3. This is how the data tables look like ? www.reach-solar.com
  • 4. ? CUF: What do you expect? www.reach-solar.com
  • 5. Frequency Distribution CUF Values 16 Highest CUF 21.3% Lowest CUF 12.2% 14 6 3 2 3 3 2 1 0 12% to 13% 13.1% to 14% 14.1% to 15% 15.1% to 16% 16.1% to 17% 17.1% to 18% 18.1% to 19% 19.1% to 20% 20.1% to 21% Above 21% The Difference: Absolute: 9.1% | Factor: 1.75 www.reach-solar.com
  • 6. Frequency Distribution CUF Values 16 14 6 3 2 3 3 2 1 0 12% to 13% 13.1% to 14% 14.1% to 15% 15.1% to 16% 16.1% to 17% 17.1% to 18% 18.1% to 19% 19.1% to 20% 20.1% to 21% Above 21% Top Performers vs. All Others 94.00% 6% 92.00% 60.00% www.reach-solar.com 8% 40%
  • 7. ? Is this problem specific to India? www.reach-solar.com
  • 8. No, it is not! “Nevertheless, the PV systems evaluable per region showed significant deviations in their respective yields. Although located in a similar environment, the yield variation in some regions was up to 20 %. Assessment of the quartiles revealed 75 % of the plants underperforming compared to the top performing plants. Another 5 % were included in the group of outliers due to their overall yield being too low for this study. The significance test proves that, due to the sufficiently high number of evaluable PV plants, the statistical results of our study reflect the actual yields of the PV systems to a high degree.” - Source: Survey on yield of photovoltaic plants 2012 in Germany by Meteocontrol (Prof. Dr. Henirk te Heesen et al. www.reach-solar.com
  • 9. ? Is it because of the panels? www.reach-solar.com
  • 10. CUF vs. Technology 9 7 Note: There are 28 c-Si, but only 22 Thin Film installations in this sample! 7 7 5 3 2 1 1 1 1 2 1 1 1 1 0 12% to 13% 13.1% to 14% 14.1% to 15% 15.1% to 16% 16.1% to 17% 17.1% to 18% 18.1% to 19% 19.1% to 20% 20.1% to 21% Above 21% Thin Film www.reach-solar.com c-Si
  • 11. CUF vs. Technology II 12% to 13% 13.1% to 14% 14.1% to 15% 15.1% to 16% 16.1% to 17% 17.1% to 18% 18.1% to 19% 19.1% to 20% 20.1% to 21% Above 21% Thin Film Bottom line: There are very good and not so good performing plants either with Thin Film or c-Si! www.reach-solar.com c-Si
  • 12. ? Is it because of the size? www.reach-solar.com
  • 13. CUF vs. Average Installed Capacity 17.55 15.40 14.59 11.73 11.67 14.14 11.67 10.22 6.67 12% to 13% 13.1% to 14% 14.1% to 15% 15.1% to 16% 16.1% to 17% 17.1% to 18% 18.1% to 19% 19.1% to 20% 20.1% to 21% Above 21% Average Installed Capacity Bottom line: Do larger / smaller plants perform better? One thing is for sure: The sample of 50 plants is too small to give an answer. www.reach-solar.com
  • 14. ? So what can we learn from this? www.reach-solar.com
  • 15. A Skeptical Thesis • We do not have enough information, because • Generation Data and CUF do not provide the right or enough insights www.reach-solar.com
  • 16. ? Why have we done this exercise? www.reach-solar.com
  • 17. Reasons • #1: To understand better the limitations of CUF and generation data • #2: To build awareness that there might be a problem & that there is room for improvement • #3: Not specific to India – happens also in Germany / Europe so it affects the whole industry www.reach-solar.com
  • 18. CUF: What goes into the equation… • Units generated • Installed Capacity • Time (e.g. 1 year) www.reach-solar.com CUF Energy Measured (kWh ) Installed Capacity(kW ) 8760 h
  • 19. CUF: What goes not into the equation… • Ambient Temperature • Panel Temperature • Irradiation at Project Site www.reach-solar.com • Grid related aspects • Availability • Frequency
  • 20. PR: A Different Approach • Instead of asking: What was achieved without asking about the frameconditions and circumstances www.reach-solar.com • Ask: What could have been achieved considering all the frame conditions?
  • 21. Comparison of CUF and PR for a PV System in Germany (2012) 77.58% 81.54% 78.90% 78.63% 76.00% 75.90% 72.03% 74.42% 76.39% 19% 21% 78.32% 10% 14% 21% 19% February March April May June July Performance Ratio [%] www.reach-solar.com 3% 9% 4% January 70.60% 4% 25% 18% 72.80% August CUF [%] September October November December
  • 22. Takeaways • #1: Great components do not automatically lead to high performing plants • #2: Design has a huge impact (but not only electrical design!) • #3: CUF is a good tool but will not provide the complete picture • #4: PR is also a tool for quality management www.reach-solar.com
  • 24. Component Capacity Nos Installed Plant Capacity Lost Chance of Detection 1 Panel 250Wp 4000 0.025% “0” 1 String 5kWp 200 0.5% Not very likely 1 SCB 50kWp 20 5% Possible 1 Inverter 500kW 2 50% Likely 1 Transformer 1000kW 1 100% Most likely *1MW plant – not a real application; simplified for illustration Design for Reliability www.reach-solar.com
  • 25. “Classical Approach” •#1: Panels •#2: Inverter •#3: Temperature www.reach-solar.com
  • 26. “Classical Approach” •#1: Panels •#2: Inverter •#3: Temperature Price www.reach-solar.com
  • 27. Min. Performance and Typical Performance of c-Si Panels vs. Time in Operation (Aging Process) 100% 98% 96% 94% 92% 90% 88% 86% 84% 82% 80% 0 5 10 Min. Performance 15 20 Typical Performance Performance of Panels www.reach-solar.com 25
  • 28. Simplified Output Power vs. Ambient Temperature 120 Standardized Output Power 100 80 60 Temperature De-Rating 40 20 0 0 10 20 30 40 50 Ambient Temperature Performance of Inverter www.reach-solar.com 60 70
  • 29. Is focusing on Panels and Inverters enough? www.reach-solar.com
  • 30. Drainage & Civil Works www.reach-solar.com
  • 32. Component Capacity Nos Installed Plant Capacity Lost Chance of Detection 1 Panel 250Wp 4000 0.025% “0” 1 String 5kWp 200 0.5% Not very likely 1 SCB 50kWp 20 5% Possible 1 Inverter 500kW 2 50% Likely 1 Transformer 1000kW 1 100% Most likely *1MW plant – not a real application; simplified for illustration SCB: Mission Critical Component www.reach-solar.com
  • 35. Component Capacity Nos Installed Plant Capacity Lost Chance of Detection 1 Panel 250Wp 4000 0.025% “0” 1 String 5kWp 200 0.5% Not very likely 1 SCB 50kWp 20 5% Possible 1 Inverter 500kW 2 50% Likely 1 Transformer 1000kW 1 100% Most likely *1MW plant – not a real application; simplified for illustration Transformer: Mission Critical Component www.reach-solar.com
  • 38. Component Capacity Nos Installed Plant Capacity Lost Chance of Detection 1 Panel 250Wp 4000 0.025% “0” 1 String 5kWp 200 Not very likely 1 SCB 50kWp 20 0.5% 5% 1 Inverter 500kW 2 50% Likely 1 Transformer 1000kW 1 100% Most likely Possible *1MW plant – not a real application; simplified for illustration Mounting Structures: Mission Critical Component www.reach-solar.com
  • 39. No, it is not specific to India! www.reach-solar.com
  • 41. Conclusion • Plant Efficiency • EPCs and Owners Engineers – educate your clients about plant efficiency (PR vs. CUF) • Quality Control • Install and use a SCADA system to monitor and document the plant performance • System Deployment • Deploy a system – focus on all design aspects (not only electrical, but also civil) • Share • Share your generation and performance data to set a benchmark www.reach-solar.com
  • 42. Top Performing Plants Now 80 / 20 Top Performing Plants in Future www.reach-solar.com
  • 43. Contact Us REACH Solar Consulting P Ltd. S3 Team Business Center 98 V M Street, Mylapore Chennai 600004 India c/o CHROSIS UG Hallerstrasse, 27 74549 Wolpertshausen Germany madhavan@reach-solar.com sebastian@reach-solar.com www.reach-solar.com