Day 7 Commissioning Maintenance Safety Dos and Donots.pptx

Solar Power Plant commissioning.

1. Commissioning, Maintenance, Safety, Quality, Dos and Donts M r. J Chatterjee Capacity Building Program on Rooftop Solar PV

2. Laying of AC and DC Cables Types and sizes of AC & DC cables required for a particular solar PV system vary depending on the amount of current required and the distance to be covered. Key factors that need to be considered while laying AC and DC cables are : Cable Selection Routing and Pathways Spacing and Separation Insulation and Protection Codes and Standards Compliance Safety Measures Maintenance and Accessibility

3. Earthing and Laying of LAs Installation of earthing pits must comply with proper norms and requirements to ensure good grounding. Lightning Arrestors (LA) protect the solar PV system from lightning strikes by safely diverting high voltage to the ground. Components include rods or conductors placed at strategic points. LAs are positioned to offer the best protection, typically at the highest points of the installation.

4. Mounting of Inverter Inverter converts DC from the solar panels into AC, which can then be used by home appliances or fed into the grid. It requires proper ventilation and should be placed in a location that minimizes exposure to harsh conditions.

5. Mounting of AJB+ACDB+GIP Array Junction Box (AJB) should be weatherproof and should be accessible for maintenance. AC Distribution Box needs to be compliant with IEC codes and easily accessible. Grid Interface Protection (GIP) ensures that the solar PV system operates safely with the grid, protecting against several issues like over-voltage, under-voltage, and frequency variations.

6. General Arrangement Diagram Designing a solar PV system layout that maximizes efficiency, enhances maintenance convenience, minimizes manpower and ensures safety and security is very crucial.

7. Single Line Diagram (SLD) A single-line diagram of a solar PV system configuration depicts the electrical connections and system components in a simplified form. It shows the flow of power from the solar panels to the load or grid connection.

8. Comissioning of Plant A commissioning checklist for a solar rooftop PV system installation project is a detailed list of tasks and requirements that must be performed and validated before the system is considered fully operational and ready for use.

9. Maintenance

10. Introduction Maintaining the solar power system through Operation and Maintenance (O&M) is one of the most important strategies to guarantee optimal generation.

11. Maintenance: Different Aspects

12. Maintenance Action Plan

13. Maintenance: The Do’s Performing diagnostics for your system Visual examination Electrical inspection Verifying parts & connection Checking switches Removing obstacles from panel Securing cables & fittings Testing emergency shut-off

14. Maintenance: The Don’ts Avoid cleaning your panels with any abrasive instruments & chemical solvents Avoid climbing on your roof alone without a climbing partner & appropriate personal & climbing protection Avoid pouring hot water on cold panels or very hot water on heated panels as they can both lead to panel cracks Avoid using hard water & high pressure hoses for cleaning

15. Inspection & Maintenance Schedule A detailed inspection & maintenance schedule is mentioned below: Inspection & Maintenance Schedule

16. Quality

17. Definition & Philosophy Quality is defined as the degree of excellence. Quality assurance is essential for rooftop solar plant installation. Philosophy of Quality is based on five aspects: Tangibility Efficiency Durability Aesthetics Reliability

18. Cost vs Quality Quality is not a directly proportional function of cost rather it is inversely related. Finding the right balance between Cost and Quality is crucial.

19. Quality Control Report Detailed Quality Control Report must be filled up by the project manager to maintain uniform quality throughout the project A detailed format have been shared below: ..\Final Bangladesh project doc\Quality control Format.xlsx

20. Joint Inspection Format of joint inspection report stated below: ..\Chapter wise documents- Bangladesh\DPS Joint commissioning certificate.docx

21. S afety

22. Introduction S afety is one of the most crucial aspects of working at the site. Safety measures should be followed starting from the site inspection, designing, erection and commissioning to operation of the solar plant. Who se Safety one may consider in a Solar Project? Safety of the people working in the project Safety of the materials Safety of the project sites

23. Personnel Safety Proper training of staff members in handling emergency situations quickly & effectively. Medical clearance certificate is mandatory. Mandatory work permits before commencement of work. Regular monitoring of employee’s physical health. Strict guidelines prohibiting the use of inebriants while working.

24. Personnel Protective Equipment (PPE) Mandatory use of Personal Protective Equipment (PPE) such as safety shoes, safety helmets, safety eyewear, reflecting jackets, gloves and safety belt, full body harnesses with permanent lifelines for all workers and all jobs.

25. Electrical Safety Because solar power plants create and transport large amounts of electricity, employees need to be well-versed in the safe handling of electrical equipment. They should also be able to recognize the dangers of working with live electrical components and take appropriate precautions.

26. Lockout/ Tagout procedures Lockout/tagout measures must be used to de-energize and secure electrical and mechanical equipment before beginning any maintenance work. This guarantees the workers' safety.

27. Fall Protection When performing operations that require heights, like maintaining solar panels, employees should be outfitted with the appropriate fall protective gear. They ought to make use of safety gear like safety harnesses.

28. Emergency Response Plan It is necessary to have a well-organized emergency response plan in place to deal with possible risks and guarantee worker safety in an emergency. Frequent simulated exercises improve readiness for unforeseen circumstances.

29. Fire Safety Fire detection & suppression equipment, as well as frequent fire safety training for employees, are essential for solar power plants. By carrying out these stimulated exercises, awareness will be raised & employees will be ready for such circumstances.

30. Handling Hazardous Materials To maintain a safe working environment, hazardous products such as cleaning chemicals for solar panels must be handled and disposed of properly. Employees need to be aware of the safety measures that must be followed when handling these products.

31. Safety Measures During Installation Solar modules handling: Before unpacking, keep that in ventilated, dry condition, avoid sharp objects for unpacking the modules, avoid stepping into the modules, prevent electrical production of modules before installation, modules exposed to sunlight should not be touched.

32. Safety Measures During Installation Unloading & lifting of solar modules: An expert is required to secure the module attachment to the crane or forklift. Lifting equipment is maintained safely by installation staff to prevent mishaps. Physical obstacles are removed from the way if the modules are manually lifted onto the rooftop.

33. Safety Measures During Installation Module installation & routing of cables: All installation personnel undergo regular training to prevent any harm to the modules during installation. A comprehensive inspection is performed to make sure the cable is not damaged during routing. The process should be completed under the strict supervision of licensed engineers or safety officers.

34. Safety Measures During Installation Clamp fixing & earthing: There is a place to tie a safety lanyard to the monkey ladder, which is utilized for installation. In addition, the ropes can be tailored to specific projects. The boring machine's speed is constantly kept below 10 km/h during the procedure. When handling backfilling compounds, connecting the electrical panel, and attaching electrodes, the team cautiously follows the guidelines and wears cotton, PVC, and leather gloves. During the welding of the system, aprons, face shields, and welding goggles are also used.

35. Safety Measures During Installation Inverter: Proper positioning and ventilation to avoid overheating followed by proper wiring and connections to prevent accidental contacts and short-circuits. Regular maintenance and inspection to prevent damage or corrosion on inverters followed by grounding and earthing to minimize the risks of electrical shocks. Solar inverters with automated shutdown mechanisms should be installed to avoid any hazards or damage during fire or any other emergency.

36. Safety Measures During Installation Battery: The batteries connected with solar inverter should be kept rust free and proper lubrication must be done to avoid any damage to the batteries. The water level in the batteries should be checked every three months to maintain its good condition.

37. Safety Measures During Installation AJB, ACDB & DCDB: AJB itself acts as a protection system by safeguarding solar panels & other components of the system from overloading or overcurrent conditions. It includes protective devices like fuses. Installation of ACDB and DCDB boxes ensure protection of solar panels & inverters from high voltages and short-circuits.

38. Safety Measures During Maintenance Cleaning modules: Use of gloves, avoid detergent or brush etc. Tightening of solar panel bolts. Using solar panel protective covers. Installing lightening rods near arrays. Cables should be kept dust free to prevent electrical damage. Tightening of connections to prevent electrical shocks or fire. Shutting down of entire plant to avoid major accidents before onset of cyclones or heavy rainfall.

39. Protections of Rooftop Solar Plant After the system design is completed, implementation of safety and protection mechanisms is necessary to ensure the system's safety and reliability. Wiring techniques and grounding : Proper grounding of all system components and wiring is critical to prevent static charge accumulation and lowering the risk of electric shock. Surge protection devices (SPDs) : SPDs safeguard the inverter and electrical equipment against voltage surges and other electrical disturbances. Earthing and Lightning Arrestor : Earthing is critical for safety in a solar PV system. It provides a path for fault currents and reduces the possibility of electrical shocks and fire hazards.

40. Fire Safety Measures Using certified and high-quality components that satisfy industry standards lowers the danger of failure and overheating. Correct cable and component sizing ensures that all system components can withstand expected electrical loads without overheating. Fire-resistant materials: Using fire-resistant materials and cable insulation helps prevent the spread of fire in the event of an electrical accident. Adhering to dedicated IEC standards and keeping a fire extinguisher ready on site is essential.

41. SOLAR POWER PLANT FAULTS

42. Introduction For steady generating efficiency, PV systems need to be maintained constantly. Failures in PV systems can result in serious life threats, safety concerns, damage to system components, & an overall reduction in the system’s operating efficiency.

43. Types of Faults

44. Physical Faults Physical faults include panel defects such as internal PV cell damage, panel cracks, degradation faults & shattered panels.

45. Physical Faults Solar panel discolouration: Occurs due to prolonged exposure to environmental factors like sunlight, rain, and dust & formation of ethyl vinyl acetate (EVA). Hotspots: They are usually the result of heat buildup, which can be made worse by things like restricted airflow through the solar panel system (such a protective cover).

46. Environmental Faults Environmental faults includes shade defects caused by bird dropping, dust buildup, cloud movement & tree shadows.

47. Electrical Faults Electrical faults include line-line faults, arc faults, MPPT faults, open-circuit faults, ground faults, short circuit faults & islanding operation faults.

48. Electrical Faults Potential-induced degradation (PID) is the term for performance loss brought on by stray currents in crystalline solar modules. Up to 30% of power may be lost as a result of this consequence.

49. Electrical Faults Solar Panel Diode Failure: Overheating in high temperatures, excess voltage from mismatched panels, reverse polarity from wiring problems, manufacturing flaws, lightning strikes, moisture problems leading to corrosion, and natural aging are some of the reasons why solar panel diodes fail.

50. Shading Faults When PV modules are shaded by nearby buildings, trees, or overhead power lines, shading takes place. PV array shading can be either non-homogeneous, with an uneven reduced irradiation across the panels, or homogeneous, with a balanced lowered irradiation throughout the panels.

51. Arc Faults This kind of defect is brought on by a frequent, high-power electrical discharge through an air gap between conductors. Two types of arc faults: series arc faults, which are typically caused by solder separation, corrosion at the connection, damage from rodents, cell damage, or abrasion from various sources. Second, faults with parallel arcs caused by insulation failure in conductors that convey current.

52. Line-line Faults An accidental short-circuit between two locations with different voltage potentials is known as a line-line fault. Intra string faults, or short-circuit faults between two locations on the same string, and cross string faults, or short-circuit faults between two locations on different threads, are the two most prevalent types of line-line faults.

53. Ground Faults Earth-grounding conductors (EGC) are commonly used to ground the metallic components of photovoltaic arrays in order to safeguard consumers against potential electric shocks. Any inadvertent connection between an EGC and a current-carrying conductor that causes current to flow to the ground is referred to as a "ground fault."

54. Thanks