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Design and Estimation of 1MW Utility Scale Solar PV Power Plant
Design and Estimation of 1MW Utility Scale Solar PV Power Plant
Design and Estimation of 1MW Utility Scale Solar PV Power Plant
Acknowledgement
This analysis based report is done for the readers of my previous report 1MW Utility Scale SPV
Power Plant, mainly for the readers from South region of INDIA as they are asking repeatedly
about the probability and feasibility-technical & Financial-of a SPV power plant in their region.
At the same time it’s not possible for me to design a report for each and every state from South
India, so I took Chennai city. Also the previous report was not so detail, was very basic and
meant to the readers who want to get an overview on how a utility scale power plant works.
Now, in this report, I discuss about in depth. From panel’s selection to CB sizing all are
presented in very detail. Hope, this time you get a strong knowledge on designing and
estimation of 1MW solar PV power plant. Unlike the previous report, the financial aspect
discussed at the end of the paper. In this paper, the financial assessment has done in very detail
and considering the current scenario of SPV market including the cost of solar PV modules,
inverters’ cost, cable, transformer etc. prices and the funding, interest rate.
And if you have any queries or need clarification, please contact at info@renewpowerzone.in or
amrit.mandal0191@gmail.com .
Disclaimer
The presented data here are NOT TAKEN from any copyright materials and not showing under
my name. The meteo data collected from NASA website and NREL database which is free over
the internet. Designing of PV system is totally based on the practical experience of the author.
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Site consideration: this design has been done by considering the PV modules & array will be
ground-mounted and the site-elevation angle taken 30 .
Cost Estimation: 1MW Solar PV power plant cost estimation has done considering the current
PV market scenario (Sept-Dec 2013), so after few months the cost may vary according the
market.
CAD design & layout: I have not uploaded/attached the CAD design. If anybody interested in
setting up the plant then only contact at the given e-mail ids to get the design file.
Transmission & wheeling losses: Here, in this report, while doing the technical assessment, the
distance from nearest substation to the 1MW solar PV power plant taken within 1.5 KM and so
the wheeling losses considered as 3% of total power transmission. And in the financial
assessment, no wheeling charges have been considered.
Design Criteria: While designing & estimating the technical components & solutions, all the
required/applicable standard design codes have been considered. Mainly the IEC (International
Electrotechnical Commission) Codes, IS codes from BIS have been considered thoroughly.
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Contents
1) Introduction 4
2) Project details 5
3) Location metrological details 6
4) Determination of optimum tilt angle 7
5) Solar power plant overview 8
6) Module selection & sizing 9
7) Inverter selection & sizing 11
8) Transformer selection 12
9) Other protective devices including switch gear details 13
10) Cable sizing & selection 14
11) Civil works details 16
12) Performance analysis & simulation 17
13) Timeline of the project 21
14) Operation & maintenance structure of the plant 22
15) Financial calculation, estimation of NCF, Payback period 23
16) Guide on selection of various components 27
17) Conclusion 28
18) About the Author 28
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Introduction
India is densely populated and has high solar insolation, an ideal combination for using solar power in
India. India is already a leader in wind power generation. In the solar energy sector, some large projects
have been proposed, and a 35,000 km2 area of the Thar Desert has been set aside for solar power
projects, sufficient to generate 700 GW to 2,100 GW. Also India's Ministry of New and Renewable
Energy has released the JNNSM Phase 2 Draft Policy, by which the Government aims to install 10GW of
Solar Power and of this 10 GW target, 4 GW would fall under the central scheme and the remaining 6
GW under various State specific schemes.
The Electricity Act, 2003, paves way for an innovative approach to solve our country’s power problems.
It has paved the way for a competitive environment; open access to existing transmission and
distribution network to transmit electricity across regions; de-licensing of generation, captive power and
dedicated transmission lines; licensing of distribution and supply companies and the restructuring of
State Electricity Boards.
The Ministry of Power has mandated to promote cogeneration and renewable sources for Power
generation under Nodal agencies and hence it will play a major role in mainstreaming renewable energy
sector. The advantage or renewable resources includes their capacity to produce energy without
producing carbon-based warming and polluting agents into the atmosphere. The financial cost of its
applications is not always cheap but if the environmental costs of using fossil are accounted for,
renewable energy wins hands-down. There are also indirect savings on health and its costs as there are
no harmful emissions.
In the above backdrop, YOUR COMPANY NAME has decided to set up a 1/1000 MW/KW Solar Power
Plant. This Detailed Project Report (DPR) brings out all technical details and overall costs justifying the
selection of the project. The total power generation is envisaged to be 1050KW from Solar Photovoltaic
Cell. It is a very important document that is required for Environmental Impact Assessment (EIA) studies,
fixation of tariff, finalizing Power Purchase Agreement (PPA) and also for submission to Financial
Institutions for obtaining project funding. The total project cost is expected to be Rs ___ Crores and the
average cost of generation is expected to be Rs. 7.5/kWh (ASSUMED).
For this project, poly-crystalline technology based 3rd generation Solar PV modules will be used. Along
with this, highly efficient, photon-tested string inverters going to be integrated to the system. These
technologies are the best in the industry. So, It’s clear that our project is not compromising with the
quality of the materials and or the components which obviously led this project to success.
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Client’ details
Country India
Location CHENNAI
Contact id ABC@XYZ.COM
Contact Person abc
company ABCXYZ
Purpose Power generation &
distribution to State utility grid
Site Location/Layout
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Solar Irradiation
7
5 Solar Irradiation
KWh/m2/day
31
Air & earth temperature-monthly
30
29
28
Air temperature
27 earth temperature
26
25
24
23
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On the 21st December, the sun will rise 87° east of due south and set 87° west of due south.
On the 21st March/21st September, the sun will rise 91° east of due south and set 91° west of due
south.
On the 21st June, the sun will rise 95° east of due south and set 95° west of due south.
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System Overview
SPV Array Peak Power 1082KWp
No. of SPV strings 206
Connection of PV modules in each string Series
Inverter 20KW MPPT based 3 phase string Inverter
Inverter Type/Topology MPPT & Transformer Less
Total no. of Inverters 53
Strings/Inverter 4/1
Modular Components
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Detail Solar Inverter Specification & Design Details
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Transformer Sizing
Design Criteria IS-2026 / IEC-60076
Transformer type Power transformer, core type with oil-immersed ;
650C winding temp rise
Cooling type ONAN(Oil Natural Air Natural)
Rated KVA 1250KVA
High Voltage rating 11000V
Low Voltage Rating 460V
Nominal impedance 4.7%
Impedance tolerance 7.5%
Nominal secondary amps 1250A
Max SC withstand current 20KA/3s
HV connection DELTA
LV connection Wye
Operating frequency 50Hz
Tap changer ±5% of full load capacity
Protective devices
components Specification Quantity
DC Disconnects String to inverter= 1000V, 15A; 2 pole 206
(As per IEC-60947)
Switch gear Rated voltage=12KV; 1
Rated main busbar current(Max)=1250A;
SC withstand capacity = 25KA/3s
Dynamic capacity= 50KA
IP55
Circuit breakers (MCCB) Inverter to Busbar= 60A 3p; 53
(NOT required if Inverter has inbuilt busbar/Panel box to transformer= A 3p; 1
protection)
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Cable Sizing
DC Side Cables (strings to inverter)
Design criteria IEC-60811 & IEC-60216
Cable material Copper
Single cable length per string to inverter 70 ft
Cross section per string 4 mm2
Voltage drop 0.18V
Relative power loss reference to Max DC power 0.07%
Max withstand temp. Normal condition Short-circuited
condition
900C 2500C
Max withstand current capacity 42KA/1sec
Conductor type Stranded
Insulation material XLPE
LT Cables (Inverters to busbur/distribution panel)
Design criteria IEC-60228 & IEC-60811
Cable material Copper
Max Single cable length per inverter to panel box 60 ft
Cross section 16 mm2
Voltage drop (3phase) 0.46V
Relative power loss reference to Max AC nominal 0.23%
power
Max withstand temp Normal condition Short-circuited
condition
900C 2500C
Max withstand current capacity 2KA/1sec
Conductor type Stranded
Insulation PVC
HT Cables (from distribution panel to feed-in point)
Design criteria IEC-60502
Cable material Al
Cable length from distribution panel to feed- 25 ft
in point
Cross section 185mm2
Voltage drop (total) L1 1.37V
L2 1.37V
L3 1.37V
Relative power loss reference to Max AC 0.57%
power
Voltage grade 11KV(UE), heavy duty
SC withstand current capacity 26KA @1s
Insulation XLPE
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Line Losses
DC Side AC Side Total
Total cable length 8120 ft 3070 ft 11180 ft
Cable cross section 4 mm2 16 mm2 +185 mm2 4 mm2 +16 mm2 +185
mm2
Power loss @ nominal 35 KW 5 KW 40KW
operation
Relative power loss @ 0.07% 0.76% 0.83%
nominal operation
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CIVIL WORKS
Live Loads estimation of control room + admin building (as per IS 875:1987)
parameters details Remarks
Roof load 1750 kg/ m2 As per IS-456
Ground floor load Control room 18000kg/m2 As per IS-456
Office 5000kg/ m2 IS-456
Piping load 50 kg/ m2 As per IS-456
Electrical + HVAC 26 kg/ m2 As per IS-456
Seismic load As per IS-456
Roof drainage
Roof drain heads 6
Construction details
Interwall
Cement : Sand 1:6
Interwall thickness 230mm
Parapet walls
Cement : Sand 1:4
thickness 115mm
Steel work Reinforced bars will be provided
as per IS 800:2007
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Solar Paths at site on monthly basis Reference Incident energy in collector plane
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•As per design requirement, proper land selection & acquisition processed.
Land •Time required 1 month
acquisition
•Power Purchase Agreement(PPA) with private power purchaser need to be finalized at a feasible rate.
•Required time is 15 working days
PPA
•Preparation of Detailed Project Report including technical feasibility of the project prepared.
•Time required 6 working days.
DPR
•Arrangement of finance/fund for the project from nationalized or private financing agency with significant interest rate
and equity share will be finalized.
finance •Required time for this stage is 1 month.
•After finalizing PPA and arrangement of fund for the project, procurement work starts including preparation & finalizing of
vendor selection, BOM, BOQ, order placing, follow-ups of delivery to site/warehouse.
procurement •Estimated time for this step is 1 month.
•After the processing of procurement, first civil construction at the site starts for PV mounting structure set-up and
control-room, administrative building. Finishing the civil works, PV installation & all electrical construction works including
the Grid Evacuation will be processed.
construction •Estimated time for this whole work is 2 months.
•Commissioning of the plant by authorized govt. body or certified 3 rd party will be done followed by Completion of project
execution.
commission •required time for this step is 6 working days.
ing
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operation
Plant manager
manager
maintenance
Maintenance Supply chain Accounts
Engineer
engineer(E&IE) executive executive
(Mech)
control room
Technician1 Technician2 Skilled labour1 skilled labour2
technician
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Total expenses over the year for plant O&M and staffing = 2,000,000
This expense is considered for regular maintenance cleaning of PV array, checking the status of
inverter, cable-fault checking, emergency maintenance & replacement of components and
annual salaries of O&M team of the plant.
Loan Interest rate is @12% over 70% of total project cost which shall be completed within next
7 years (the rest 30% as equity shares).
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41) 40 876,105 559,879 316,226
42) 41 876,105 565,478 310,627
43) 42 876,105 571,133 304,972
44) 43 876,105 576,844 299,261
45) 44 876,105 582,613 293,492
46) 45 876,105 588,439 287,666
47) 46 876,105 594,323 281,782
48) 47 876,105 600,266 275,839
49) 48 876,105 606,269 269,836
50) 49 876,105 612,332 263,773
51) 50 876,105 618,455 257,650
52) 51 876,105 624,640 251,466
53) 52 876,105 630,886 245,219
54) 53 876,105 637,195 238,910
55) 54 876,105 643,567 232,538
56) 55 876,105 650,002 226,103
57) 56 876,105 656,502 219,603
58) 57 876,105 663,068 213,038
59) 58 876,105 669,698 206,407
60) 59 876,105 676,395 199,710
61) 60 876,105 683,159 192,946
62) 61 876,105 689,991 186,114
63) 62 876,105 696,891 179,214
64) 63 876,105 703,860 172,246
65) 64 876,105 710,898 165,207
66) 65 876,105 718,007 158,098
67) 66 876,105 725,187 150,918
68) 67 876,105 732,439 143,666
69) 68 876,105 739,763 136,342
70) 69 876,105 747,161 128,944
71) 70 876,105 754,633 121,472
72) 71 876,105 762,179 113,926
73) 72 876,105 769,801 106,304
74) 73 876,105 777,499 98,606
75) 74 876,105 785,274 90,831
76) 75 876,105 793,127 82,979
77) 76 876,105 801,058 75,047
78) 77 876,105 809,068 67,037
79) 78 876,105 817,159 58,946
80) 79 876,105 825,331 50,774
81) 80 876,105 833,584 42,521
82) 81 876,105 841,920 34,185
83) 82 876,105 850,339 25,766
84) 83 876,105 858,842 17,263
85) 84 876,105 867,431 8,674
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1000000
900000
800000
700000
600000
Installment
500000 EMI
Monthly Principle
400000
Monthly Interest
300000
200000
100000
0
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67 70 73 76 79 82 85
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SCADA/RMS 1. Draker
Cables 1. Havells
2. Finolex cables
3. RR Kabels
4. Anchors
Isolator 1. ABB
2. Schneider Electric
3. Megawin
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Conclusion
I’d like to thank you for reading the whole paper. Hope you have got clear view on design &
estimation of 1MW utility scale Solar PV Power Plant. Though I have discussed about the
technical part as well as the financial part in detail, I might have been forgot to add anything
more important. So, you are most welcome to give your valuable feedback & suggestion on this
report. At the end, I discussed about some companies for the components. I have chosen these
companies because their products are fulfilling my design criteria. It is not that I’m representing
these companies and their products.
About Myself: I’m a Solar PV professional currently working with a solar EPC company as
Project Engineer. I’ve done B.Tech in Electrical Engineering & holding a PG certificate in
Advanced Solar Energy from delft Technical University, Netherlands.
Personally I provide technical consulting including site survey, technical design, CAD design,
preparation of DPR, guide in procurement & Construction.
Read solar PV related articles & learn about new technologies at- www.renewpowerzone.in
THANK YOU
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