TÜV Rheinland. Quality Monitor Quality Assurance and Risk Management of Photovoltaic Projects.

Transcription

1 TÜV Rheinland. Quality Monitor Quality Assurance and Risk Management of Photovoltaic Projects.

2 Global Market Leader Solar Power Plant Qualification and Testing & Certification of Solar Products More than 30 years experience in the field of solar energy Global network of more than 200 solar experts More than 12 GW inspected PV plants world wide (Europe, North America, South America, Central America, Asia and Africa) Research and development in the area of power plant optimization and module qualification (characterization and life time assessment) Active participation in the important standardization committees TÜV Rheinland test sites TÜV Rheinland operates accredited solar laboratories and test sites around the globe (Germany, Italy, India, P.R. China, Taiwan, Japan, South Korea, USA, Saudi- Arabia) 2

3 Content Introduction, Quality Weaknesses, Market Situation Quality Monitor, Field Experience, Results of a TÜV Rheinland Study Loss of Revenue, Risk Management How to minimize Risks 3

4 Quality Weaknesses in the PV Market Product quality is often not given due to the market situation (high competition, low financial recourses, personnel fluctuation, change of suppliers, lack of quality assurance knowledge) Project assumptions and feasibility are imprecise energy yield prediction too optimistic, cleaning concept missing or insufficient, lack of fixed contract requirements, lack of experience How to solve these problems? Low quality of planning and installation use of sub- and sub-subcontractors, high competition, lack of knowledge and experience, tight commissioning deadlines, weak quality assurance during construction Bankability of involved parties often not given unstable market situation, choose of Tier-1 manufacturers is not only a criteria for bankability, warranties are often not reliable 4 June 10, 2015 TÜV Rheinland Quality Monitor Solar 2015

5 Quality Monitor 2015: Basis and Results of a TÜV Rheinland Study Basis of the study: Categorization: TÜV Rheinland has more than 12 GW plants inspected world wide (Europe, North America, South America, Central America, Asia and Africa) Basis of the study are > 100 plants (100 kwp - 30 MWp) (Main regions: Germany, Europe, RoW) Two periods ( / Q ) Particularly Serious Defects (PSD) Immediate action to prevent plant breakdown is required Serious Defects (SD) Plant operation is possible but defects must be repaired Less Serious Defects (LSD) No compelling need for action but monitoring of development is recommended 5

6 Cause of Defects in PV Power Plants TÜV Rheinland Data 2014/ Q / Q Main findings: 30 % of power plants show particularly serious and serious defects (incl. safety issues) or large number of issues > 50 % of defects are caused by installation errors Installation faults 55% Miscellaneous 1%! Systematic quality assurance is required Pant inspections and maintenance are imperative Environmental influence Maintenance 5% 5% Product defects 9% 25% Documentation & planning faults 6

7 Particularly serious Defects in PV Power Plants Immediate action to prevent plant breakdown is needed 2012 / / Q Cabling Modules Modules 33% 48% 19% Infrastructure & environmental Potential equalization & grounding 7% 8% 13% Inverter 11% 9% Connection & distribution boxes Mounting structure Inverter Mounting structure 4% 4% 16% Connection & distribution boxes 28% Cabling 7

8 Serious Defects in PV Power Plant Plants Operation is possible but defects must be repaired 2012 / / Q Cabling Modules 13% 31% 14% Connection & distribution boxes Modules 27% 32% Cabling Infrastructure & Environmental Transformer station 6% Miscellaneous 6% 2% 7% Potential equalization & grounding 5% Inverter 16% Mounting structure Infrastructure & environmental Transformer station Miscellaneous Potential equalization & grounding 2% 2% 3% 4% Inverter 9% 13% 8% Mounting structure Connection & distribution boxes 8

9 Examples for Particularly Serious Defects (PSD), Serious Defects (SD) and Less Serious Defects (LSD) Components Category Defects Example Modules Inverter Connection & distribution boxes PSD SD LSD PSD SD LSD PSD SD LSD PID Potential Induced Degradation Undervalued power, glass breakage, delamination Burned junction box Defective backsheet Browning, serious micro cracks Module frame damaged Snail tracks Out of operation Insulation faults Not suitable for local environmental conditions Inverter door without filter Missing Cover Burned connection, surge protector out of operation Water in distribution box Wrong fuse rating Missing labels Dirt inside Delamination Burned Connection 9

10 Examples for Particularly Serious Defects (PSD), Serious Defects (SD) and Less Serious Defects (LSD) Components Category Defects Example Mounting structures Cabling Potential equalisation & grounding PSD SD LSD PSD SD LSD SD LSD Unstable, damaged Weak anchorage Missing edge protection Screw not fixed in place Module clamp not fixed Corrosion Connector charred/burned Damaged cable Different connector type Not UV resistant Improper insulation Wrong dimensioning Not fixed (loose) routing Missing or improperly secured potential equalisation No corrosion protection Bad foundation Corroded socked/plug 10

11 Examples for Particularly Serious Defects (PSD), Serious Defects (SD) and Less Serious Defects (LSD) Components Category Defects Example Weather station LSD No maintenance or calibration logs Wring location or orientation of sensors Infra-structure, environ-mental influence SD LSD Shading Land-slide due to bad drainage system Fence damaged Refuse at the plant Communication & monitoring SD LSD No communication link to inverter Incorrect data transmission Shading by vegetation Transformer station PSD SD LSD Panic lock blocked Insecure access Improper cooling system Refuse in station 11

12 Loss of Revenue Risks On-Site Risks Technical Risks Safety Risks Logistical Risks Political Risks Wind Lightning Snow, hail and ice Pollution Dust Rock fall Land slide Earthquake Flood Shading Animals Performance and yield Malfunction Degradation Aging Maintenance cost Repair Replacement Statics Appearance Accessibility Electric shock Electric arc Fire Statics Mechanical integrity Ergonomics Theft Vandalism Production delays Shipping Supply Raw materials Transport damages Change in legal situation (laws) Application procedures Social aspects Permissions Financial market risks Financial Risk 12

13 Examples of Loss of Revenue Factors >30% Max. Min. 5% 4% 3% 2% 1% 0% 13

14 Potential Induced Degradation (PID) Performance killer number one: potential induced degradation (PID) (occurs in cases of high voltage, sensitive module/material combinations and damp environments e.g. caused by condensation, high humidity) Reversible process through grounding or counter-potential (investments required) Test results of a PID test of PV modules from large-scale PV systems -15% -75% -95%! Knowledge of PID sensitivity of PV modules is necessary All material combinations of a module must be considered in order to declare it PID-resistant! 14

15 Influence of Soiling Daily cleaning of one system, no cleaning of the other Section 1: both systems cleaned Section 2,3,4: both systems not cleaned from D on: rainfall and no manual cleaning Cleaning period [d] Power degradation [%]! Yield losses > 5 % within 1 week are possible Site specific cleaning concept is required

16 Global Energy Yield Benchmark Mild mid latitude Marine West Coast Mild mid latitude Mediterranean Tropical Humid, Savanna (subtropical) Desert, potential sandstorm impact! Energy Label includes evaluation of: - Temperature - Angular dependency - Low irradiance - Spectral dependency 16

17 Global Energy Yield Benchmark First results Italy 12 % Variation between technologies Germany 13 % India 23 % Arizona 21 % Saudi Arabia Not available yet Data is not compensated for availability losses; Measurement uncertainty of the MPP tracking: 0.5 % Measurement uncertainty of STC value for referencing: 2.5 % Label Normalized Energy Yield (1 year data) Arizona Italy India Indien Germany Köln Label Normalized Energy Yield [Wh/Wp] ! Choice of technology and optimised product is crucial for high energy yield and return of investment.

18 Unforeseeable Events: Example Hail Intensity and frequency of severe hail storms has increased Insurance claims can be very large Identification of damaged modules is not obvious (not only glass damage, but also cell cracks are relevant) Product qualification only covers 25 mm ice balls Some insurers require hail resistance classified products or increase premium (30, 40, 50 mm) Adapted product testing and life time simulations required Hail risk by claims Source: 18

19 Unforeseeable Events: Example Fire Research project indicates status quo and derives further safety measures More than 250 cases with PV+fire indicated, including PV as source of fire Project results Rescue squads (e.g. fire fighter) do not face additional risks from PV Risk analysis (FMEA): failures can be avoided in an early stage: High quality products Proper installation Valid O&M concept and practice Rules are verified to objectify the risk BIPV is still a challenge: construction regulations are relevant 19

20 Safety and Performance of Electrical Storage Systems Investigation of the safety of battery systems in all conceivable application scenarios during its life cycle. Foster the acceptance of future technologies. Stakeholders, operators, fire fighters and installers shall be informed and not fear a new technology that shall not pose personal risks. Development of tests, which permit a comparable qualification of PV storage systems (safety, performance and recyclability). Verification of whole system performance expectations 20 June 10, 2015 TÜV Rheinland Quality Monitor Solar 2015

21 Reliable Switches in DC Photovoltaic Application Investigation of harsh environmental conditions of switches in PV systems. Analyzing, evaluating and testing of all conceivable failure scenarios. Provide information to all stakeholders including installers, operators, rescue squads and fire fighters. Development of test criteria for string and module switches which lead to a new specification/standard. 21 June 10, 2015 TÜV Rheinland Quality Monitor Solar 2015

22 Quality Weaknesses in the PV Market Product quality is often not given due to the market situation (high competition, low financial recourses, personnel fluctuation, change of suppliers, lack of quality assurance knowledge) Project assumptions and feasibility are imprecise energy yield prediction too optimistic, cleaning concept missing or insufficient, lack of fixed contract requirements, lack of experience How to solve these problems? Low quality of planning and installation use of sub- and sub-subcontractors, high competition, lack of knowledge and experience, tight commissioning deadlines, weak quality assurance during construction Bankability of involved parties often not given unstable market situation, choose of Tier-1 manufacturers is not only a criteria for bankability, warranties are often not reliable 22 June 10, 2015 TÜV Rheinland Quality Monitor Solar 2015

23 Strategy to improve Quality on the PV Market The quality improvement must be initiated by investors, banks, insurers and owners Project related product testing and characterization (pretesting and batch related testing) Experienced third party project feasibility study, energy yield prediction on the basis of full product characterization and site influences Quality assurance and risk management is the key! Quality assurance of installation, installer education and qualification, inspections during installation, comissioning test, periodic inspection, monitoring Ensure high product quality with the prevention of later claims (power, yield, safety, reliability, durability), risk assessment 23

24 Thank you for you attention! TÜV Rheinland Am Grauen Stein, Cologne, Germany Phone: , Fax Internet: References: 24