Quality Assurance of Solar PV Plants 22 March 2016, 9th ASEF, Ritz-Carlton, Beijing, PRC
Steven Xuereb, PI Photovoltaik-Institut Berlin PIPI Photovoltaik-Institut Berlin AG Photovoltaik-Institut Berlin AG
Overview 1. PI Berlin and International Cooperation 2. Role of Quality Assurance (QA) in PV Plants 3. QA during Development Phase 4. QA during Construction Phase 5. Experience in Operational Plants 6. Evaluation of PV Plant Quality 7. Summary
PI Photovoltaik-Institut Berlin AG
PI Berlin PV Independent engineering consultancy since 2006
IEC accredited module lab in Berlin and China
PI Photovoltaik-Institut Berlin AG
PI Berlin
PI Photovoltaik-Institut Berlin AG
International Cooperation Partner:
Physikalisch-Technische Bundesanstalt – PTB German National Metrology Institute and an Implementing Agency of Ministry of Development Cooperation (BMZ)
Countries:
Indonesia, Mexico, Senegal, Tunisia
Objectives:
Promotion and strengthening of quality standards and infrastructure in the PV industry
Stakeholders:
Energy ministries, national institutes, universities, manufacturing and trades companies
Tasks:
• • • •
LER Senegal – Measuring Station
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In-country meetings with stakeholders; Review of local institutions and standards; Evaluation of existing technical capacity and skills; Recommendations for QA requirements for PV
CERER Senegal – Centre for RE
CETIME Lab in Tunisia – Climate Chamber
PI Photovoltaik-Institut Berlin AG
Role of QA in PV Plants Stakeholder
Interest/Risk
General QA Type
Project Developer Protect high risk initial investment; completion of project
Review of documentation and energy estimates
Lender
Protect main recourse which is project itself
Technical due diligence
Investor/Owner
Protect long term investment
Technical due diligence
EPC Contractor
Meet customer obligations; reputation; warranties
Acceptance and performance testing
Module Supplier
Meet customer requirements; reputation; warranties
Factory and laboratory testing
PI Photovoltaik-Institut Berlin AG
Role of QA in PV Plants
Contracts & Permits Module Quality
System Performance
Designer Capability
Technical Design, Documentation
?
Safety and Function
EPC Contractor
ElectroOperations & Mechanical Maintenance installation
PI Photovoltaik-Institut Berlin AG
QA during Development Phase EPC Contract / Module Supply Agreement Risk:
Under-performing plant; long-term reliability; unenforceable warranties
Cause:
Insufficient performance tests; no independent module batch testing; unclear contracts
QA Mitigation:
• •
•
EPC contractor and module supplier must have own QM plan and have reputable experience EPC Contract must include: • Independent inspection of plant before take-over • Performance test procedure to verify performance ratio and capacity with clear pass/fail criteria • Clear criteria for performance deficits during warranty period Module supply agreement must include: • Independent inspection and batch testing of production modules • Clear criteria for refusal of modules and warranty claims • Confirmation of bill of materials of modules delivered
PI Photovoltaik-Institut Berlin AG
QA during Development Phase Performance test criteria:
PI Photovoltaik-Institut Berlin AG
QA during Construction Phase i. Module Production – Factory Audits and Production Supervision
Risk:
Production of poor quality modules leading to underperformance and reliability concerns
Cause:
Stated quality program is not being adhered to; different materials are being used
QA Mitigation:
• Inspect production facility before production of modules to recommend changes • Monitor daily manufacturing process as well as operator and equipment workmanship • Supervise performance and quality tests to ensure they conform to norms • Verify that the components of the supply chain match the agreed bill of materials
PI Photovoltaik-Institut Berlin AG
QA during Construction Phase Factory audits and production supervision:
Lay up area
Cleaning and Flashing
PI Photovoltaik-Institut Berlin AG
QA during Construction Phase ii. Module Production – Independent Batch Testing
Risk:
Production of poor quality modules leading to underperformance and reliability concerns
Cause:
Manufacturing defects at cell level; sub-standard materials used
QA Mitigation:
• Test sample of modules at an independent testing laboratory • In addition to IEC standard test, apply tests such as PID, EVA gel content, and peel tests • Ensure testing process conforms with supply agreement and that pass/fail criteria from contract are applied
PI Photovoltaik-Institut Berlin AG
QA during Construction Phase
PI Photovoltaik-Institut Berlin AG
QA during Construction Phase iii. Module Delivery and Installation Risk:
Damaged modules are installed leading to underperformance and reliability concerns
Cause:
Modules damaged during transportation from supplier to project site or damaged by contractor during installation
QA Mitigation:
• Supervision of handling and storage of module crates • Sample testing of modules after unpacking using visual inspection and electroluminescence (EL) testing • Sample testing of modules after installation using infrared and EL testing • Ensure pass/fail criteria from contract are applied
PI Photovoltaik-Institut Berlin AG
QA during Construction Phase Cracks caused by transportation:
Cracks caused by installation:
PI Photovoltaik-Institut Berlin AG
QA during Construction Phase iv. End of Construction – Pre take-over Risk:
Take-over of plant with significant deficiencies and final payment to contractor before correction of defects
Cause:
Plant not installed in accordance with contract specifications and industry standards
QA Mitigation:
• Comparison of as-built documentation with technical design • Inspection of all plant components and systems • Performance testing using calibrated measurement station to compare guaranteed performance ratio with actual • Ensure all conditions precedent to take-over from contract are met (e.g. documentation, grid code, training, etc.)
PI Photovoltaik-Institut Berlin AG
QA during Construction Phase Final acceptance inspection:
Shading and Mismatch Standard Curve
Measured Curve
PI Photovoltaik-Institut Berlin AG
Experience in Operational Plants Challenge: Date:
Troubleshooting of Performance Degradation 2013-2014
Project • Installed power: 4 MW Description: • 12000 poly and monocrystalline modules • Ground mounted grid connected plant Location: Italy Operation:
3 years
Inspection:
• Documentation review • Performance analysis • High Volume EL and IR
PI Photovoltaik-Institut Berlin AG
Experience in Operational Plants Key Findings: Modules – 80% significant cracking; 20% hotspots; PID Performance: ~10% lower yield; individual modules ~ 20% power deficit Cause: manufacturing and transportation Impact: 4000 modules (1/3) replaced; anti-PID retro-fit QA Mitigation: Batch testing of modules during production process Quality requirements for transportation PI Photovoltaik-Institut Berlin AG
Experience in Operational Plants Challenge:
Technical Due Diligence for refinancing of operating plant 2014 – 2015 Date: Project • Installed power: 15 MW Description: • 60000 poly-crystalline modules • Ground mounted grid connected plant Project Location: Services:
Sub-saharan Africa • • • •
Documentation review Site inspection with IR Tests in lab Report with risk assessment
PI Photovoltaik-Institut Berlin AG
Experience in Operational Plants Key Findings: Field: Modules - delamination, snail trails and PID Lab: Modules failing PID, EL and peel tests Cause: PID sensitive modules; poor lamination process Performance: to-date not affected QA Mitigation: Batch testing of modules during production process System design evaluation with respect to PID PI Photovoltaik-Institut Berlin AG
Evaluation of PV Plant Quality Q2
Q1
Feasibility study
Stage Purpose Term
Development
Detailed design
Installation
Commissioning
Q3
Operation
Q1
Q2
Q3
Development
Construction
Operation
Financial Close with Lender Technical Due Diligence (TDD)
Pre-takeover, Final Payment Provisional Acceptance Certificate (PAC)
Re-financing, Sales/Acquisitions Technical Due Diligence (TDD)
PI Photovoltaik-Institut Berlin AG
Evaluation of PV Plant Quality 5% 20 % ElectroMechanical installation
Competence of O&M
10 % Commissioning safety and functionality
10 %
30 % Technical design, as built documentation
System performance
5%
20 % Contracts and permits
Q3
Module quality and module performance
PI Photovoltaik-Institut Berlin AG
Evaluation of PV Plant Quality Each topic has its checklist, which consists of sub-items
Q1
Q2
Q3
pass/fail criteria
pass/fail criteria
pass/fail criteria
Q1: > 800
Q2: > 1300
Q3: > 1200 PI Photovoltaik-Institut Berlin AG
Evaluation of PV Plant Quality
PI Photovoltaik-Institut Berlin AG
Summary Quality assurance plan is a critical element of PV projects for all stakeholders involved and at the various project stages Lenders and investors are requiring a significant level of quality control as a condition to their financing of PV projects During the development phase it is important to ensure performance requirements are in EPC/Module contracts During the construction phase it is important to monitor the manufacturing of the modules, perform independent testing and conduct an in-depth acceptance inspection before take-over Quality inspection methodologies should be applied that include detailed checklists of all project components to quantify the level of technical risk associated with the project
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PI Photovoltaik-Institut Berlin AG
Contact Thank you for your attention! www.pi-berlin.com Steven Xuereb Head of Business Unit PV Systems
[email protected] +49 30 8145264-403 (office) +49 171-4500888 (mobile) Wrangelstrasse 100 10997 Berlin, Germany
PI Photovoltaik-Institut Berlin AG