MODULE LEVEL POWER MANAGEMENT DECREASES PV COSTS AND RISKS
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1 MODULE LEVEL POWER MANAGEMENT DECREASES PV COSTS AND RISKS Levent Gun Ampt LLC 4850 Innovation Drive Fort Collins, CO ABSTRACT Module-Level Power Management (MLPM) is a new category of products in the solar industry consisting of DC/DC converters and DC/AC microinverters that manage power on each PV module. To date, MLPM solutions have presented a spend more, get more value proposition in which overall system costs go up, but increased production of energy and monitoring features are intended to justify the expense. For the most part, this has limited the adoption of MLPM to residential and small-scale installations where the presence of significant amounts of non-uniform shading can sometimes justify the incremental cost of such solutions. This paper offers a new point of view that MLPM can lower both the cost and risk of PV projects to create significant value. This spend less, get more approach enables MLPM to thrive even in large commercial and utility-scale applications. 1. INTRODUCTION The PV industry is passing through a period of contradiction. On one hand, fragile global economic conditions, restricted flow of investment capital, and the steady decline of incentives make PV projects challenging to finance and put pressure on both the top and bottom line. In this environment, the drive to lower PV system costs has intensified and so has vendor and technology risk. Hypercompetitive pricing by component suppliers threaten margins and destabilize the risk profiles of even top tier suppliers. Meanwhile, the potential rise of next-tier, lower cost structure suppliers may help to achieve lower dollar per watt ($/W) targets, but will also raise questions of quality, support risks and even supplier longevity. On the other hand, innovation is thriving in the PV industry as leading players continue to invest in new technologies and business models to grow the market and provide attractive returns to shareholders. Module-Level Power Management (MLPM) solutions have received significant investment and attention in the PV market as a disruptive technology with the promise to create significant value. The question is: can MLPM thrive in a cost driven market to increase return on investment (ROI) and lower investment risk at the same time? This paper looks at both the cost and risk factors for assessing ROI and shows that the right MLPM solution creates significant value in PV power plants. 2. THE RISE OF MLPM Module-Level Power Management (MLPM) is a new category of products in the solar industry that was introduced within the last few years. The category consists of DC/DC converters and DC/AC microinverters that manage power on each PV module. Fig. 1: Ampt DC/DC power converter with maximum power point tracking (MPPT) on each PV module and optional wireless communication capabilities. 1
2 The MLPM category has grown rapidly and is expected to reach a significant portion of the PV market over the next few years. Module-level electronics are projected to grow almost four times the growth rate of the broader PV market through ASSESSING THE VALUE OF MLPM When assessing the value of MLPM, PV project developers select solutions that help to lower the net cost of energy produced /kwh also referred to as the levelized cost of energy (LCOE). This savings in LCOE can either be passed along in the form lower electricity rates, or kept by the developer to increase project returns. Lowering LCOE is a balancing act to optimize its basic drivers: performance, capital cost, and operating costs. While performance and operating costs matter, today s PV market is hyper-focused on capital cost. Decision makers are increasingly driven by $/W as commodity economics take hold. Simply put, most developers want to spend less on their PV system to continue to be competitive and meet ROI goals over time. To visualize this PV industry trend, see the leftside graph in Figure 3. To date, the typical MLPM solutions have presented a value proposition that is counter to industry cost trends. These typical MLPM solutions require developers to spend more for PV systems when adding MLPM with the expectation of increased energy generation. The graph in the center of Figure 3 shows this spend more, more output approach. While the payoff of this approach is real for some installations, it is typically hard to estimate accurately and limits MLPM from adoption in large-scale projects where there is minimal non-uniform shading and the promise of increased generation therefore does not justify the additional investment. The preferred MLPM solution helps PV developers spend less and get more output. The right-side graph in Figure 3 shows the opportunity to generate superior returns by selecting a spend less, more output MLPM solution. Fig. 3: The preferred MLPM solution lowers the cost of PV systems and increases energy output to achieve the highest return on investment (ROI). How is it possible to spend less for a PV system by adding MLPM to achieve the highest ROI? The answer is provided below. 4. LOWER SYSTEM COSTS WITH MLPM Project developers want to lower the cost of their PV systems. Preferred MLPM solutions can accomplish this by removing more cost from the PV system than is added by module-level electronics. Specifically, the preferred MLPM solution should: Decrease installed DC Balance of System (BOS) costs Decrease installed inverter costs The following sections describe each of these cost reductions. Together, they more than pay for MLPM on day-one. 4.1 MLPM Decreases DC BOS Costs Up To 50% PV system engineers work hard to optimize designs that lower installed costs without sacrificing performance or quality. They focus on details ranging from the weather and local safety codes to rising copper prices. Despite the many complexities of system design optimization, engineers have consistent needs like using fewer and less expensive parts and minimizing voltage drop losses. Designing systems with longer series strings of PV modules helps to accomplish these objectives. Preferred MLPM products let system designers put up to 40% more modules per string compared to conventional systems. They also lower the current carrying capacity requirements of cabling and components. This lowers the 2
3 cost of wiring, combiners, and related hardware and labor by up to 50%. With MLPM, string length is no longer limited by PV module open circuit voltage (Voc). Instead, preferred MLPM products limit output voltage to a value less than Voc while still delivering maximum power. Figures 4 and 5 show the difference in string length between conventional systems and those with MLPM products that have voltage output limits to enable string stretch. Fig. 6: Ampt DC/DC converters allow optimized cabling to lower DC BOS costs up to 50% and simplify wiring. To see the advantage of MLPM designs over conventional systems, consider the half-megawatt block design comparison in TABLE 1. Fig. 4: Conventional PV system (without MLPM). String length is limited by PV module Voc. Fig. 5: Ampt DC/DC converters allow string stretch by limiting voltage output to a value less than PV module Voc. In addition to voltage output limits, preferred MLPM products have current output limits. These limits remove the need for system designers to build in current carrying capacity margin for over sun conditions when specifying cable thickness, fuse and other component ratings while still complying with safety codes. MLPM products with voltage and current output limits allow system designers to optimize and simplify cabling layouts to achieve the lowest cost design as illustrated in Figure 6. TABLE 1: DC BOS COST DECREASE WITH MLPM Example: 587 kwdc Fixed Ground PV System (600V) Conventional With MLPM Modules per string Number of Combiners /0 cable 824 ft. 3/0 cable 1294 ft. 4 AWG cable ft. 10 AWG cable ft. 12 AWG cable 1440 ft. Labor hours 311 hrs. 136 hrs. Copper volume 20% decrease Materials $ 39% decrease Labor $ 57% decrease Designing PV systems with more modules in each series string further enables lower inverter costs by delivering a higher input voltage to the inverter. The benefits associated with this are explained in the next section. 4.2 MLPM Decreases Inverter Costs Up To 50% PV inverters must accept the wide range DC output of a PV module under varying temperatures and levels of irradiation. This wide voltage range means there will be times when the inverter is operating either with a high input voltage and low input current, or with a low input voltage and high input current. So while the inverter is capable of handling high input voltages and currents at the same time, it never does. This underutilized capability drives up inverter cost. 3
4 The voltage and current limits unique to some MLPM products allow the inverter to operate closer to its maximum voltage and current simultaneously. This increases the rated power of existing inverters. Preferred MLPM solutions help inverters achieve higher power utilization by: Performing MPPT at the module-level Allowing more modules per string (higher voltage) Enabling inverters to operate at a higher and narrow voltage range Inverters deployed with MLPM can operate at a higher and narrow DC input voltage range to drive a higher AC output voltage and deliver up to two times more power. Doubling the rated power is equivalent to lowering the $/W cost by half (Figure 7). deployed with Ampt DC/DC converters. This 64% increase in power equates to a 40% savings in inverter cost per watt. The following table shows the difference between LTi s inverter when deployed with and without MLPM. TABLE 2: INVERTER COST DECREASE WITH MLPM Example: LTi REEnergy Container PVmaster-Station 64% power increase lowers $/W by 40% with MLPM Standard With MLPM Input (DC) Min/Max input voltage 500/900 V 800/900 V MPP range V V Narrow Rated input voltage 550 V 825 V Higher Rated input current 2 x 630 A 2 x 630 A Output (AC) Rated output voltage 330 V 545 V Higher Rated output current 2 x 540 A 2 x 540 A Rated output power 610 kw 1000 kw 64% Fig. 7: Ampt DC/DC converters enable the inverter to deliver up to twice the power at the same cost, effectively reducing $/W by half. While the precise power increase and cost savings benefits from MLPM varies by inverter, one example is the inverter manufactured by LTi REEnergy (Figure 8). Fig. 8: LTi PVmaster-Station delivers 64% more power when combined with Ampt DC/DC converters. The LTi PVmaster-Station increases the rated output power of its standard inverter from 610 kwac to 1000 kwac when Inverters deployed with MLPM deliver more power at a significantly lower cost. They also dissipate less power per kilowatt than the same inverter operating without MLPM. This takes into account conduction, switching and high frequency AC inductor losses. With lower losses per kilowatt, inverters with MLPM are more efficient and reliable. 5. MORE ENERGY WITH MLPM PV system designers recognize the potential to increase PV system energy output by putting maximum power point tracking (MPPT) closer to the source of generation. A variety of approaches exist to capture this potential additional energy such as central inverters with multiple MPPT inputs, string inverters, and module-level electronics like micro-inverters and DC/DC converters. Basically, the more granular and efficient the power management is, the higher the system production will be under changing environmental and system conditions over the lifetime of the power plant. For readers less familiar with the harvest benefits of MLPM, the next section describes some of the sources and ranges of incremental energy achieved with module-level electronics. 5.1 Performance Improvement with MLPM Putting MPPT on each PV module captures the full power of each module despite current and voltage variances (i.e. mismatch) between modules and strings. Sources of mismatch can be caused by variations in module nameplate 4
5 output, degradation, or environmental conditions, such shade, soiling, temperature, and orientation. Figure 9 illustrates the ability of module-level DC/DC power converters to recover power losses caused by mismatch between PV modules in a series string. Fig. 10: Ampt measured and modeled performance improvement on a 20 year old system. Fig. 9: Ampt DC/DC converters boost and buck output voltage to deliver the full available power of each PV module. We have collected years of module, string, and array level data to analyze the dynamics of mismatch in PV systems, and to understand the short and long term benefits of adding MLPM. In our experience, the expected year-one harvest improvement is modest on well designed and maintained systems without shade. However, over a lifetime, the amount of energy recovered by MLPM is significant. Following are representative examples of field data showing the magnitude of performance benefits that we have observed by adding module-level DC/DC converters to PV systems. 5.2 Capture Energy Lost Due To Non-Uniform Degradation PV modules degrade non-uniformly over time, increasing mismatch and lowering production. To understand the magnitude of this lost energy, and the potential of MLPM to recapture it, we collaborated with an independent laboratory to study a 20 year old utility-owned PV system. We found that MLPM recovers approximately 40% of degradationrelated energy losses over the lifetime of a system. Figure 10 shows measured losses of 29% in the 20 year old system without MLPM. Adding DC/DC converters recovered 12% (nominal) of that energy. The extra energy was captured with MLPM by abating the effects of mismatch between modules and strings. The effects of non-uniform module degradation can be electrically and statistically modeled to project the average loss profile of a system. The graph above shows the modeled loss profile of the PV system with and without MLPM using measured data from year twenty. The area between the two lines represents the calculated 5.6% incremental energy recovered by MLPM, assuming the system had zero mismatch in year one. PV module technology has improved over the last twenty years, and modern modules may not degrade at the same level as those in this study. Today, system designers plan for 0.3% to 0.5% annual module degradation in top-tier silicon modules. Those losses occur non-uniformly and result in mismatch that nearly doubles the impact of module degradation on system-level production. MLPM products will recover those degradation losses to add on the average 4% more energy over a system lifetime. 5.3 Capture Energy Lost Due To Manufactured Mismatch The day-one incremental energy production of MLPM depends on a number of variables including how uniformly the PV modules are sorted (current and voltage) and installed. Any manufactured variance creates mismatch losses in energy due to the serial connection of modules into a string, and the parallel connection of strings into a central inverter. The following graph shows the effect of manufactured mismatch on system losses, and how MLPM can recapture these losses. In this example, strings were tested with and without module-level DC/DC converters. Those with converters captured a higher percent of available energy from each string. 5
6 5.5 More Energy in Real-World Conditions In the real-world, PV systems experience imbalances from a variety of sources throughout a day and over a lifetime. Whatever the source of mismatch, MLPM will prevent that condition from debilitating other modules and strings within the array. Fig. 11: Ampt DC/DC converters increased baseline performance 1.7% on a system without obstructive conditions (e.g. shade, soiling) Figure 13 shows field data from a commercial deployment that represents a typical rooftop system. It did not have excessive shade, failed modules, or other conditions that might exaggerate mismatch. The inverters with MLPM demonstrated a 4.2% average increase in production during the first year of measurement. The expected lifetime harvest gain on this system is 8-12%. It is important to note that there were no obstructions (e.g. shade, soiling) effecting the system. It was perfect other than built-in variances. 5.4 Capture Energy Lost Due To Environmental Conditions The diverse and variable environmental conditions in which PV systems must operate have a significant impact on system production. The higher the current or voltage mismatch between modules and strings, the more energy there is for MLPM products to recover. Shade, temperature variances and soiling are common sources of environmental mismatch. The graph below shows MLPM recovery of losses from shade. It compares strings of PV modules both with and without DC/DC converters. The reference string has no shade applied, while strings 1 and 2 each are partially shaded. MLPM typically captures 40-70% of the lost energy caused by environmental mismatch conditions like shade. Fig. 13: Performance increased 4.2% in the first year on the inverters having PV modules with Ampt DC/DC converters. 5.6 MLPM Is A Natural Evolution In System Architecture The potential to increase energy production in a PV system by putting MPPT closer to the source of generation is well understood by designers. It is also well understood that the value of additional energy produced by increasingly granular MPPT must be weighed against any additional cost. Microinverters cost more per watt than string inverters, and string inverters cost more per watt than central inverters. When is the extra cost worth the extra energy? This cost/benefit discussion continues to fuel debates in engineering circles and industry panels. This paper offers a new point of view that it is no longer true that putting MPPT at the module-level necessarily means higher costs. In fact, Section 4 has shown that system costs can decrease by putting DC/DC converters at the module-level. Fig. 12: Ampt DC/DC converters recover 40-70% of lost energy from shade. Once MLPM no longer adds cost to a system, the increased energy benefits are a more obvious economic advantage across virtually every type and size of PV application. From 6
7 this view, MLPM becomes a natural next evolution in PV system architectures to maximize return on investment. 6. HIGHER RETURN ON INVESTMENT WITH MLPM As described in Section 3, the preferred MLPM solution lowers the total cost of PV systems and produces more energy. This spend less, more output approach to MLPM generates superior returns over both conventional PV systems, and typical MLPM offerings that increase system costs rather than lower them. To assess the cost/benefit of preferred MLPM solutions, it is useful to think in terms of present value. How much does the MLPM cost? What DC BOS and inverter cost savings can I realize by adding MLPM? What is the net present value of the extra energy that MLPM will generate during the system life? Figure 14 compares the incremental cost of adding MLPM to a system with expected benefits. It shows that every dollar spent on MLPM returns up to five dollars of value measured in present dollars. While the amount of cost savings and added energy will vary from system to system, the implication of the above case study is clear: MLPM can play a significant role in increasing project returns. 7. LOWER RISK WITH MLPM Risk assessment is an integral part of any financial analysis. Most often, the higher the potential returns of a project, the higher the associated risk of that investment. The goal, therefore, is to get the highest return possible within your tolerance of risk. In the context of PV power plants, the trade-off between risk and return often manifests itself in the selection of system components. For example, a system designer may desire to purchase less expensive PV modules to get a higher return, only to discover that those modules are of lower quality. Cost went down, but risk went up. This intuitive relationship is depicted in Figure 15. Fig. 15: Cost reduction initiatives must be balanced against a potential increase in project risk. Fig. 14: Ampt DC/DC converters lower system cost and increase production for up to 5x return on incremental investment. In the graph above, MLPM costs are more than offset by DC BOS and inverter savings to lower installed system cost. Higher energy production and potential savings in operation and maintenance (O&M) further increase ROI. System and financial assumptions in this example include: Installation type: Large fixed tilt rooftop PV module: 240 watts System life: 25 years Avg. daily insolation: 4.36 hours Electricity value: US$0.20/kWh feed-in-tariff for years 1-20; US$0.11/kWh at 2.5% inflation for years Discount rate: 6% In fact, there are many types of risks in today s PV systems. Table 3 lists types of risk and examples. TABLE 3: COMMON RISKS IN PV PLANTS Risk Types Environmental Operational Technology Financial Vendor Compliance Examples Lost energy from shade & soiling Failed modules cause strings to drop Legacy PV modules become unavailable Degrading annual production PV module warranty support Ground / Arc fault fire hazard 7
8 PV project developers, engineers, operators, owners and investors try to mitigate these risks while optimizing project economics. Too often, projects cannot be financed as developers are unable to find the needed cost/risk balance. MLPM helps remove barriers to project finance by both decreasing costs and lowering risks. Cost savings were covered in Section 4 above. Examples of project risk mitigation are provided in the Table 4. Note that the items in Tables 3 and 4 relate to each other. The risk identified in Table 3 is lowered by MLPM as described in Table 4. TABLE 4: MLPM LOWERS RISK IN PV PLANTS Risk Types Environmental Operational Technology Financial Vendor Compliance MLPM Lowers Risk by: Correct mismatch between modules & strings Prevent string & inverter drops Provide greater visibility for optimized O&M Mix different modules in a system Recover non-uniform degradation losses Track module performance Prevent, interrupt, locate faults 8. CONCLUSION Module-Level Power Management (MLPM) products have gained a strong foothold in residential and small commercial PV applications, and are poised to reach a wider application space. Unfortunately, typical MLPM products promote a spend more, more output value proposition that will slow adoption and limit the addressable market. However, a new breed of preferred MLPM products is now available in the market with a spend less, more output value advantage. These MLPM solutions remove more cost than they add to lower the $/W cost of PV systems. Accordingly, PV project developers should favor modulelevel electronics such as DC/DC converters that decrease the installed costs of DC BOS and inverters to more than pay for themselves on day-one. These converters deliver more energy and remove project risk compared to conventional system designs. Not all MLPM approaches have the same value proposition. But, the right MLPM solution one that lowers cost and increases energy can indeed thrive in a cost driven market and increase ROI. The examples of risk mitigation offered above are not intended to be exhaustive. However, they do point out some of the high risk factors in today s PV systems that are lowered by preferred MLPM solutions even as costs are reduced. Figure 16 captures the cost/risk advantage achievable with MLPM. Fig. 16: MLPM products can lower both cost and risk. 8
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