Session : Evolution in Renewable Energy Technologies Sriparn Saurabh Operation Manager, Energy. UL India Pvt Ltd

Transcription

1 Session : Evolution in Renewable Energy Technologies Sriparn Saurabh Operation Manager, Energy. UL India Pvt Ltd 2011 Underwriters Laboratories Inc.

2 WORKING FOR A SAFER WORLD SINCE UL founded by William Henry Merrill following 1893 Chicago World s Fair Funded and sponsored by the National Board of Fire Underwriters 1897 Published list of approved electrical devices 1901 Name of Underwriters Laboratories, Inc First UL standard published 1916 First international office opened in London 1958 Fire protection lab built 1980 UL/CCIC agreement for inspections 1988 Korea, Hong Kong & Taiwan offices open, followed by many international offices 2

3 Some keyfacts about UL TO HELP MAKE THE WORLD SAFER IN THE PLACES WHERE PEOPLE LIVE AND WORK World s leading electrical safety testing and certification company 9,000 employees Leading safety brand 22 billion UL Marks on products 100,000 products tested annually Worldwide presence 67,750 customers in 104 countries 97 labs and certification facilities across the world EXPERIENCED SAFETY ENGINEERING EXPERTS Advancing Safety Science 100 Primary Designated Engineers 26 Fundamental Safety Researchers Developing Safety Expertise 250k hours/yearly in Technical Training Engineers & Inspectors Requalification Sharing Safety Knowledge 1464 Published Standards Free* Access to Standards Public Safety Services Safety Smart Youth Safety Education Anti-Counterfeiting Program 3

4 Reliability of PV modules 2011 Underwriters Laboratories Inc.

5 Three prong Path : Reliability on PV modules To ensure appropriate design, installation, commissioning, and operation of PV systems: 1) qualifying the design for the intended application (climate zone and mounting configuration), 2) quality management systems for PV module manufacturing, and 3) system-level inspections 5

6 Applicable Standards Standard Scope PV Module Inverter PV Installation System Survaillance Description IEC series 1,2,3,4,5,7,8,9,10 ( measurement, ref devices, spectrum) IEC Parts 1+2 / UL1703 ( safety) IEC/UL 61215/ ci-s/tf IEC / UL 8703 CPV (performance) EN / UL Name plate rating and data-sheet IEC Parts Module performance testing and energy rating IEC Ammonia corrosion, IEC Salt mist test, IEC-draft PID IEC-draft Encapsulants / Back&Frontsheets EN / UL 6703 / IEC-draft Connectors for photovoltaic systems EN / UL 3730 / IEC-draft Junction boxes UL Outline for PV wires IEC Parts 1+2 /UL Inverter IEC 61727, 2004 Ed 2, Photovoltaic (PV) systems Charact. of the utility interface Local grid code requirements IEC , grid connection: Requirements installations or locations IEEE 1547 Distributed Resources Interconnected with Electric Power Systems EN Part 3 System grounding and lightning protection UL 2703 outline for mounting structures EN requirements for combiner boxes UL 4703 outline for PV wires EN / UL 6703 / IEC-draft Connectors for photovoltaic systems IEC 62124: PV stand alone systems EN system surveillance during operation IEC Grid connected photovoltaic systems Minimum requirements for system commissioning tests and inspection IEC Onsite measurements of IV characteristics IEC Grid connected photovoltaic systems Minimum requirements for system documentation UL and the UL logo are trademarks of UL LLC

7 PV Modules - Current State (Válquez & Rey-Stolle, 2008) IEC 61730/ UL1703 IEC/UL 61215/61646 Safety Performance Specialized Test Protocols (PV QA Task Force) Bankability build confidence in the module and its components to satisfy the lifetime production goals of a project. Durability/Reliability UL and the UL logo are trademarks of UL LLC

8 What is Bankability? UL formula for creating confidence and trust in PV modules, the manufacturer and supply chain: + Safety testing - IEC 61730/ UL Performance testing - IEC/UL 61215/ Statistical Sampling representative cross section of production + Extended Stress testing configurations based on IEC/UL 61215/61646 (durability) + Conditional testing specialization for operating environment (durability) + Factory Inspection assess product consistency within a facility and across production sites (quality/reliability) + Company and Product Profile assess sustainability of the company, product and module warranty = Bankable PV Modules UL and the UL logo are trademarks of UL LLC

9 UL Bankability 1. Independent Performance Testing (extended) 2. Factory Inspection and QA 3. Company/Product Profile UL and the UL logo are trademarks of UL LLC

10 Performance Testing Test # Service Description 1 PID Sequence (ULdefinition) Evaluate module for stability under high potential. 2 Extended Temperature Cycle(TC) Evaluate modules for temperature changes and resistance to thermal mechanical stressors beyond typical. 3 Extended Damp Heat(DH) Evaluate PV modules to moisture ingress under high temperature beyond typical. (i.e high humidity applications). 4 Dry-Heat Testing Evaluate PV modules ability to withstand high temperature exposures ( i.e. dessert applications). 5 Sequential Testing Evaluate PV modules ability to withstand multiple stressors beyond standard requirements. 6 Salt Mist Test Evaluate PV modules for marine applications and corrosive environments. 7 Ammonia Test ( or other noxious gases) Evaluate PV modules for use in agriculture applications. 8 Mechanical Load (heavy load testing) Evaluate PV modules for use in heavy snow load applications. 9 Mechanical Fatigue Testing (wind) Evaluate PV module for use high-wind regions and serves as accelerated test for mechanical fatigue ( 10,000 cycles). 10 Severe Hail Impact Testing Evaluate PV modules for use in severe hail environment. 11 Sand Impact Test Evaluate PV module for dirt and sand abrasion (ie. dessert applications) 12 Fire Test Evaluate PV module for resistance to spread of flame and burn through 13 Gel Content ( via Soxleth) Evaluation of PV module lamination stack to verify production process 14 Electro-luminescence Verification of cell integrity ( generally applied after stress tests and transport) 15 Infra-Red Imaging Verification of cell integrity. Typically applied after stress tests or shipping to installation site. 16 Flash Test Sequence These services are aimed to check performance (power Pmpp) of the PV modules. Lot-by-Lot Comparison Aid in identify ng drifts and trends in manufacturing processes between shipped 17 modules UL and the UL logo are trademarks of UL LLC

11 Potential Induced Degradation Description: Evaluate module for stability under high potential. Also able to provide assessment of recovery periods. Stage 0 Stage 1 Stage 2 (PID) Test Features: UL Specific Test methodology 25 C, Aluminum foil on front plate, Usyst = 1000V EL Imaging after each stage Stage 1: 168hrs: 1000W/m² + 200W/m²: Pass/Fail: 5% power loss; 40MOhm*m² min. insulation resistance Stage 2: 336hrs: 1000W/m² + 200W/m²: Pass/Fail: 10% power loss, 40MOhm*m² min. insulation resistance Samples: 2 for each polarity + 1 spare for each BOM << Electroluminescent Imaging

12 Extended Temperature Description: Evaluate modules for temperature changes and resistance to thermal mechanical stressors beyond typical. Cycle(TC) Test Features: Per IEC/ UL 61215/61646 (heating cooling ramp has to be 100 C/h) 400 cycles (or Test-to-Fail) between (-40 C) to + 85 C c-si: Impp current thin-film: continuity check or Impp Samples: spare for each BOM Pass/Fail: TC-200: 5% power loss, 40MOhm*m² min. insulation resistance, TC-400 (or beyond): customer specific power loss, 40MOhm*m² min. insulation resistance

13 Extended Damp Heat (DH) Description: Evaluate PV modules to moisture ingress under high temperature. Test Features: Per IEC/UL 61215/ hours (or test-to-fail), +85 C, 85% RH Optional: applying a current Samples: spare for each BOM Pass/Fail: DH-1000: 5% power loss, 40MOhm*m² min. insulation resistance, DH-1500/2000 (or beyond): customer specific power loss (default: 5% for 1500h, 8% for 2000h), 40MOhm*m² min. insulation resistance

14 Dry-Heat Testing Description: Evaluate PV modules ability to withstand high temperature exposures ( i.e. desert applications) Test Features: Configured as in IEC/UL 61215/ hours (or test-to-fail), +100 C, <15% relative humidity Optional: applying a current Pass/Fail: Dry-Heat-1000: 5% power loss, 40MOhm*m² min. insulation resistance, no discolorations

15 Sequential Testing Description: Evaluate PV modules ability to withstand multiple stressors for general application use. Test Features: Per IEC/UL 61215/61646 (heating cooling ramp has to be 100 C/h) Sequential test with damp-heat, thermal cycling and humidity freeze (cycle: DH:1000h +TC:200 + HF:10) Samples: spare for each BOM Pass/Fail: DH-1000h: 5% power loss, 40MOhm*m² min. insulation resistance DH-1000+TC-200+x: power loss defined by customer (default: DH TC-200 5%, DH-1000+TC- 200+HF-10 8%), 40MOhm*m² min. insulation resistance Repeat until target power loss achieved or until major failure

16 Salt Mist Test Description: Evaluate PV modules for marine applications and corrosive environments. Test Features: Per IEC ed 2, Severity 5, 28 days Optional: applying a voltage/current Samples: spare for each BOM Pass/Fail: 5% power loss, 40MOhm*m² min. insulation resistance

17 Ammonia Test Description: Evaluate PV modules for use in agriculture applications. Test Features: IEC ed 1 Samples: spare for each BOM Pass/Fail: 5% power loss, 40MOhm*m² min. insulation resistance

18 Mechanical Load (heavy snow) Description: Evaluate PV modules for use in heavy snow load applications. Test Features: Mechanical load test per UL with applied loads of 5400, 7000 and 8000 Pa Per IEC/UL 61215/61646 Test-definition: Front side loading: Pa for 1hour each with intermediate measurements after each loading Pass/Fail: 5400Pa load: 5% power loss, 40MOhm*m² min. insulation resistance, no cracking or bending marks of/on frame or other parts

19 Mechanical Fatigue Testing Description: Evaluate PV module for use in high-wind regions and serves as accelerated test for mechanical fatigue ( 10,000 cycles) Test Features: Dynamical load test with 10,000 cyc and parameters per IEEE/ASTM 1262 UL method: positive load 1440Pa (30 lb/ft2), negative load 0 Pa for simulation of wind gusts Samples 2 Modules per mounting situation + 1 reference/spare Pass/Fail: 5% power loss, 40MOhm*m² min. insulation resistance, no breakage, no constant deformation/cracking of frame or other parts

20 Severe Hail Impact Testing Description: Evaluate PV modules for use in severe hail environment. (25mm are already performed by IEC certified modules). Test Features: IEC/UL , with ice balls of 35, 45, 55, 65 or 75 mm diameter Samples: 1 for each glass/frame type and each major design change (e.g. glass/foil to glass/glass construction) + 1 spare for each BOM Pass/Fail 5% power loss, 40MOhm*m² min. insulation resistance, no breakages

21 Sand Impact Test Description: Evaluate PV module for dirt and sand abrasion (ie. dessert applications) which can affect irradiation absorption ability resulting in loss of power output. Test Features: Procedure is based on the following standards: NATO-AECTP 300, Methode 313 IEC IEC/UL 61215/61646/ Samples: spare for each BOM Pass/Fail 5% power loss, 40MOhm*m² min. insulation resistance

22 Fire Test Description: Evaluate PV module for resistance to spread of flame and burn through. Test Features: Per UL ,31.2 (UL 790 spread-of-flame, burning brand) Samples: up to 6 modules. Pass/Fail At no time shall the brand burn a hole through the roof covering or through any part of the module or panel. At no time shall the flame spread beyond 6 ft for Class A, 8 ft for Class B, or 13 ft for Class C rating. Note: the UL1703 fire test requirements are also proposed to use in IEC

23 Gel Content Description: Evaluation of PV module lamination stack integrity, a verification of the production process. Test Features: Soxlieth Method ( 24 hrs) Differential Scanning Calorimetry (DSC) mehtod ( ~1hr) - not available Extract EVA sample (coupon) out of the laminate (1-5 grams) and deposit in solvent and measure weight percentage of non-soluables Samples: spare for each BOM Pass/Fail For encapsulation of PV the gel content should be 80% and below 90%

24 Electro-luminescence (EL) Description: Verification of cell integrity ( generally applied after stress tests and module transportation) Snapshot Test Features: EL camera snapshot of charged module ( DC power applied) Service delivered from all UL laboratories ( not field capable) Image characterization reference to UL catalog of failure attributes. Typically for customer information only unless they ask for analysis and interpretation. Pass/Fail Criteria have to be agreed between all involved parties in a project.

25 Infra-Red Imaging (IR) Description: Often used to verify module cell integrity, to verify proper field installation and discover damage that may have occurred during transit and construction. Test Features: Performed in the field the PV installation should be fully operational and run at Pmpp Pass/Fail Observational for customer information.

26 Flash Test Sequence Description: These services are aimed to check performance (power Pmpp) of the PV modules and verify the name plate rating. Test Features: Modules stabilized. Per MQT 19 of IEC series. Pass/Fail Averaged measured output power, Isc and Uoc of all samples after MQT 19 must be within uncertainty statement of Name plate of manufacturer. Typical values are % for multi c-si modules and between 1-3% for p-type Mono c-si modules.

27 Lot-by-Lot Comparison Description: Aid in identifying drifts and trends in manufacturing processes by examination of sampling of modules ( staged at factory or after shipment) Overlay of cell defect per EL imaging. Test Features: UL determines sample size with customer, based on ISO Acceptable Quality Level (AQL) Determine with customer the evaluation service suite (flash-test, EL, PID, Gel content). Samples pulled and sent to UL lab OK 15 cell defects Pass/Fail Report defect rate per sample size and lot size. Not OK 79 cell defects

28 Ongoing quality control: ISO ISO nicely defines: Sampling rates as a function of number of products Inspection levels (e.g. non-destructive / destructive) Acceptance limits for mass production Procedures to adjust sampling Switching rules Inspection levels AQL Switching rules This scheme can be applied to test from standards or to customer specific tests

29 Test Example for sampling rates and tests Inspection level Visual inspection G Flash-Test (STC) Flasher-List verification G Low-light (200W/m²) S-4 Power at different irradiance and temperatures following IEC Insulation wet-l- Test EVA cross linkage Test Lamination process/materials PID-Test (Destructive test) Electro-Luminescence Cell breakage/defects S-2 S-4 S-3 S-3 G-1 Number of modules for testing a) 80 b) 200 c) 315 a) 80 b) 200 c) 315 a) 32 b) 80 c) 80 a) 8 b) 13 c) 13 a) 32 b) 80 c) 80 a) 20 b) 32 c) 32 a) 20 b) 32 c) 32 a) 80 b) 200 c) 315 AQL (% non conforming items) a) 0 b) 0 c) 1 a) 0 b) 0 c) 1 a) 0 b) 1 c) 2 a) 0 b) 1 c) 2 a) 0 b) 2 c) 3 a) 0 b) 2 c) a) 1 b) 3 c) 5 a) 1 b) 3 c) 5 a) 0 b) 1 c) 1 a) 2 b) 5 c) 7 a) 2 b) 5 c) 7 a) 0 b) 2 c) a) b) 1 c) 1 What can you learn a) 0 b) 2 c) from that data? Plant build with 240W modules: a) 1MW, b) 10MW and c) 50MW a) 0 b) 0 c) 1 a) 0 b) 1 c) 2 a) 0 b) 2 c) 3 a) 1 b) 3 c) 5 a) 2 b) 5 c) 7 29

30 Moderate ( Munich) Damp (Hong Kong) Dessert ( Phoenix) Livestock Farms Seaside Customer Test Plan Test # Description Climate/Environment 1 PID Sequence(ULdefinition) X X X 2 Extended Temperature Cycle(TC) R X 3 Extended Damp Heat(DH) R X 4 Dry-Heat Testing X 5 Sequential Testing R R R UL and the UL logo are trademarks of UL LLC 2012 Specialized 6 Salt Mist Test X 7 Ammonia Test ( or other noxious gases) X 8 Mechanical Load (heavy snow load testing) X 9 Mechanical Fatigue Testing (wind) X X X 10 Severe Hail Impact Testing X 11 Sand Impact Test X 12 Fire Test 13 Gel Content R R R 14 Electro-luminescence X X X 15 Infra-Red Imaging 16 Flash Test Sequence X X X 17 Lot-by-lot comparison R R R X = UL Required R = Recommended Test Plan ( climate specific) UL1703/IEC61730 UL/IEC 61215/62446 Add Climate testing Add Specialized testing Add Recommended Test Plan ( general need) UL1703/IEC61730 UL/IEC 61215/62446 PID Sequence Extended TC Extended DH Dry-Heat Mechanical Load (heavy) Mechanical Fatigue (wind) Severe Hail Add Specialized testing Add Recommended 30

31 Factory Inspection and QA Realities of a production environment... 24/7 production runs impact machine tolerances Variations in the supply chain ( purchasing decisions) Human error from shift to shift, from night to day. drive need for Quality Systems (QS) Incoming goods inspection Process control and verification Outgoing product verification Training of personnel and periodic audits. UL and the UL logo are trademarks of UL LLC

32 Factory Inspection and QA UL has expertise in c-si production processes UL and the UL logo are trademarks of UL LLC

33 Factory Inspection and QA and thin-film module fabrication. UL and the UL logo are trademarks of UL LLC

34 Factory Inspection and QA Item # Name Description 1 General Information manufacturer registration, factory location, inspectors credentials, inspection type 2 Verification of Components/Materials incoming inspection, certifications, non-conforming procedures/handling, records of goods. 3 Production Control, Inspection and Routine Tests personnel qualifications, document control, process control, data recording maintenance and storage. 4 Functional Check of Test/Measurement Equipment verification of equipment operation, assurance procedures, corrective action procedures, records maintenance. 5 Products Seen in Production tests include bonding, insulation resistance, dielectric strength, leakage current, wet leakage, power control, lamination cross link, pull test. 6 Calibration of verification of equipment and reference sources, traceability, records maintenance. Test/Measurement Equipment 7 Handling and Storage components and materials storage and finished product storage compliance to standards. 8 Product Verification Tests/ in accordance to procedures, complaint to requirements, recorded and maintained. Periodic Tests 9 Inspectors Findings summary of findings 10 Quality Management System certifications 11 Manufacturers Self review and assessment Assessment 12 Customer Complaints review and assessment 13 Changes to Certified Products records review 14 Selection and Shipping of Identify sample for Samples for Re-examination 15 Inspectors Evaluation findings and summary report UL and the UL logo are trademarks of UL LLC

35 Company/Product Profile The size, reputation, financial foundation, history and product portfolio are key features that influence the credibility of PV module manufacturers. Product Portfolio UL and the UL logo are trademarks of UL LLC

36 Company/Product Profile Item # Name Description 1 Company Profile - Overview of company structure, market and product offerings. 1.1 Company Structure The structure of the company including inter and intra company relationships. 1.2 Management Structure Included here is the management structure from C suite to vice president level. 1.3 Employees This section is a summary of the historic number of employees for the company or business unit under question. 1.4 Company Timeline This section is a summary of the company timeline and major events 1.5 Project portfolio This section is an aggregation of key projects the company under investigation has been a supplier for over the company history. 1.6 Research and Development Roadmap for efficiency improvements, Previous success in R&D, Trend of R&D expenditures over the years 1.7 Company Sustainability Company future plans 2 Product Portfolio - Included in this section is the list of products the client currently manufacturers. 2.1 Module Production Capacity (kw), Volume (# of modules), Production sites, Number of employees, 2.2 Product Specifics Product manual, Product photos, Product drawings, Certifications, BOMS, 2.3 Distribution This is an overview of the distribution network for the product under investigation. We are interested only in outgoing goods. 2.4 Warranty, Claims and Insurance As part of this section we will summarize the warranty for the specific product under investigation. Along with this we will also indicate the claim rates for the particular module and the current liabilities. 2.5 Module Performance This section is a summary of the module performance at from operating projects. The source of the data, environmental and commissioning dates will also be noted in this section. 2.6 Module Power Degradation This section will summarize the module degradation of the specific module under investigation. The sources of the data may vary and this will be noted in the report. 2.7 Module Efficiency This section includes a summary of the module efficiency over time. This is to be represented by a simple graph. 2.8 Module Cost per Watt This is a summary of the module cost per watt, which is too represented by a simple graph UL and the UL logo are trademarks of UL LLC

37 Power Plant Services as Technical Partner 37

38 Thank you!! SRIPARN SAURABH M : Sriparn.Saurabh@ul.com