DPR for PV plant

8/9/2019 DPR for PV plant

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Document No. 11/60XX/001/PUN/O/R/001

Issue: B2

SunBorne Energy Gujarat One Pvt. Ltd.

Karmaria 15MW Solar PV Plant

Detailed Project Report

January 2011


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SgurrEnergy India Karmaria 15MW PV Plant: Draft Detailed Project Report

10/60XX/001/PUN/O/R/001 Revision B2 Page 2 of 59

B-139 Bizzbay, Opposite Clover Hil ls, NIBM-Undri Road,Pune 411048, Maharashtra, India.

Telephone: +91 20 65279957 / 41230967www.sgurrenergy.com

Karmaria 15MW Solar PV Plant: Detailed Project Report

SUMMARY:

This report assesses the technical feasibility of developing a 15MW solar photovoltaicpower plant proposed at village Karmaria in the Indian state of Gujarat.

The report presents plant design, indicative plot layout, nominal energy prediction andgeneral requirements for development and implementation of plant. It also assessesfinancial model, indicative budgetary cost estimates along with a review power purchaseagreement provided by SunBorne Energy.

A summary of the net nominal energy prediction, after electrical losses, is presentedbelow.

(GWh/annum)

First Year Nominal Energy Prediction after AC Losses (GWh/annum) 24.37

CLIENT: SUNBORNE ENERGY GUJARAT ONE PVT. LTD.

Contact: JAYESH JAKHETE

DISTRIBUTION :

Client:

Jayesh Jakhete

SgurrEnergy:

Arif Aga

Name Job Title Signature

Prepared by Nazish Shaikh Project Engineer

Anish Wastrad Project Engineer

Reviewed by Mukund Shendge Project Engineer

Authorised by Arif Aga

Director, Indian

Operations

Date of Issue 19January 2011 Classification: Confidential

9002/000/SF/04/023


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AMENDMENT RECORD

Issue Date of IssueChanges from PreviousIssue

Purpose of Issue

A1 07 January 11 First draft Draft for internal review

B1 17 January 11 None Draft for Client review

B2 19 January 11Following clientcomments

Draft for Client review


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Contents

1 INTRODUCTION 10

2 SITE OVERVIEW 10

3 PROPOSED PLANT OVERVIEW 11

4 SITE DESCRIPTION 12

4.1 LAND TOPOGRAPHY AND CONDITION 12

4.2 ACCESS 14

4.3 GEOTECHNICAL CONDITIONS 14

4.4 WATER AVAILABILITY 14

4.5 ELECTRICAL INFRASTRUCTURE 15

4.6 HORIZON SHADING 15

4.7 SHADING FROM OBSTACLES 15

4.8 CLIMATE 15

4.8.1 WIND 15

4.8.2 TEMPERATURE 16

4.8.3 PRECIPITATION 17

4.8.4 SOLAR RESOURCE 17

5 PV PLANT COMPONENTS 20

5.1 PVMODULES 20

5.2 MODULE STRING/ARRAY CONFIGURATION 21

5.3 INVERTERS 22

5.4 MODULE SUPPORT STRUCTURES 23

5.5

SITE SECURITY 24

5.6 REMOTE MONITORING AND DATA ACQUISITION SYSTEM 25

5.7 PVPOWER TRANSFER 28

5.8 CIVIL STRUCTURES 28

5.9 CABLING 28

5.9.1 DCCABLING 28

5.9.2 ACCABLING 28

5.10MEDIUM VOLTAGE STATION 29

5.10.1 METERING 29

5.10.2 TRANSFORMERS 29

5.11HIGH VOLTAGE STATION 29

5.12VENTILATION 29

5.13EARTHING SYSTEM 29

5.14LIGHTNING PROTECTION 29

5.15GRID CONNECTION 30

5.16SUMMARY OF SYSTEM CHARACTERISTICS 30


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5.16.1 ACHIGH VOLTAGE SYSTEM 30

5.16.2 ACMEDIUM VOLTAGE SYSTEM 30

5.16.3 ACLOW VOLTAGE SYSTEM 30

5.16.4 DCSYSTEM 30

5.16.5 SERVICE CONDITIONS 30

6 PLANT DESIGN 30

6.1 PLANT LAYOUT 30

7 REQUIREMENTS FOR DEVELOPING AND MAINTAINING A PV POWER PLANT 31

7.1 SITE ESTABLISHMENT 31

7.2 MAINTENANCE REQUIREMENTS 31

8 NOMINAL ENERGY PREDICTION 32

8.1 RADIATION IN THE PLANE OF THE MODULES 32

8.2 CORRECTIONS AND LOSSES 32

8.3

NOMINAL ENERGY PREDICTION 33

8.4 CAPACITY FACTOR 36

9 PERMITS AND LICENSING 36

9.1 PERMITTING,LICENSING AND CONTRACTUAL REQUIREMENTS 37

10 GUJARAT SOLAR POLICY AND TARIFF REGULATION 37

10.1HIGHLIGHTS OF THE SOLAR POLICY &REGULATION 37

11 PROJECT FINANCES 39

11.1PROJECT COST ESTIMATES 39

11.2OPERATION AND MAINTENANCE COST 41

11.3REVIEW OF FINANCIAL MODEL 42

11.3.1 FINANCING STRUCTURE 42

11.3.2 ANNUAL ENERGY PRODUCTION 42

11.3.3 POWER SALE 42

11.3.4 PROJECT ECONOMICS AND RESULTS 43

11.3.5 CERREVENUE 43

12 POWER PURCHASE AGREEMENT 44

13 PROJECT IMPLEMENTATION 44

14 CONCLUSION AND RECOMMENDATIONS 44

APPENDIX 1: DETAILED DESCRIPTION OF LOSSES IN NOMINAL ENERGYPREDICTION CALCULATION 46

14.1A1.1SHADING LOSS 46

14.2A1.2INCIDENT ANGLE LOSS 47

14.3A1.3LOW IRRADIANCE LOSS 47

14.4A1.4MODULE TEMPERATURE 48

14.5A1.5MODULE QUALITY 48


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14.6A1.6MODULE MISMATCH 48

14.7A1.7DCWIRING RESISTANCE 48

14.8A1.8INVERTER PERFORMANCE 49

14.9A1.9MPPLOSS 49

14.10A1.10ACLOSSES 49

14.11A1.11DOWNTIME 49

14.12A1.12SOILING 49

14.13A1.13DEGRADATION 49

APPENDIX 2: MAPS 51

APPENDIX 3: GUJARAT SOLAR POLICY 53

APPENDIX 4: TARIFF ORDER 54

APPENDIX 5: POWER PURCHASE AGREEMENT 55

APPENDIX 6: CASH FLOW STATEMENT 56

APPENDIX 7: PROJECT IMPLEMENTATION SCHEDULE 57

APPENDIX 8: PRELIMINARY GEOTECHNICAL ASSESSMENT 58APPENDIX 9: TYPICAL 15MW KARMARIA PV PLANT LAYOUT 59

LIST OF FIGURES, TABLES AND EQUATIONS

FIGURES

Figure 1: Location of the Proposed Site at Karmaria .......................................................... 11

Figure 2: Aerial view of the Proposed Site at Karmaria .................... ................................... 13

Figure 3: Land Developed for Karmaria PV plant........................................................... 13

Figure 4: Access road to the site .................................................................................... 14

Figure 5: Panoramic view from NE to NW showing horizon of Karmaria PV plant...... 15Figure 6: METEONORM Predicted Precipitation for Karmaria site. .................................... 17

Figure 7: Mean Global Daily Irradiation on a Horizontal Plane for Karmaria site ................. 18

Figure 8: Direct and Diffuse Daily Irradiation on a Horizontal Plane for Karmaria...... 19

Figure 9: Comparison of Solar Resource for Karmaria and PV Plants in Spain .................. 20

Figure 10: Indicative layout of Inter row spacing at 8tilt in summer ................................... 23

Figure 11: Indicative layout of Inter row spacing at 38tilt in winter .................................... 23

Figure 12: Site Fencing In Progress ................................................................................... 24

Figure 13: Example of Security Systems used in PV Power Plants ............................. ....... 25

Figure 14: Indicative schematic of data monitoring ............................................................. 26

Figure 15: Project capital cost breakdown. ......................................................................... 39

Figure 16: Nominal Individual year Energy Prediction ........................................................ 42

Figure 17: Summary of revenue generation ....................................................................... 43

Figure 18: CER revenue sharing ........................................................................................ 43

Figure 19: Horizon Shading at Karmaria PV plant .............................................................. 46


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Figure 20: Model of plot at Karmaria PV plant Layout as used in the PVsyst Model ........... 46

Figure 21: Incident Angle Modifier Curve Used By SgurrEnergy ........................................ 47

Figure 22: Example Curves Showing Module Efficiency Reduction at Low irradiances ...... 47

Figure 23 : Graph to Illustrate Module Efficiency Reduction with Temperature ................... 48

Figure 24: Curves to Illustrate Concept of the Maximum Power Point. ................... ............ 49

Figure 25: Map Showing Location of Terrestrial Measurement Stations used in theMeteonorm Database .................................................................................................. 51

Figure 26: India Wind Zone Map ........................................................................................ 52

TABLES

Table 1: Summary of Karmaria PV Power Plant ................................................................. 12

Table 2: Simulated Wind Speed at Karmaria site ............................................................... 16

Table 3: METEONORM 6 Temperature Data for Karmaria site. (1996 2005) .................. 16

Table 4: METEONORM 6 Irradiation Data for Karmaria, 1981-2000 .................................. 19

Table 5: PV Module Specifications ..................................................................................... 21

Table 6: PV Module Configuration ...................................................................................... 21

Table 7: System Design Parameters .................................................................................. 21

Table 8: Inverter Specifications .......................................................................................... 22

Table 9: Inverter Summary ................................................................................................. 23

Table 10: Mounting Structure Summary ............................................................................. 24

Table 11: Specifications of the SMA Sunny String-Monitor 24 (SSM24-11) ........................ 26

Table 12: Specifications of the SMA Sunny WebBox.......................................................... 27

Table 13: Specifications of the SMA Sunny SensorBox ...................................................... 27

Table 14: Description of Energy Prediction Losses ............................................................ 33

Table 15: Nominal Energy Prediction for Karmaria PV Power Plant ................................... 33

Table 16: First Year Nominal Energy Prediction ................................................................. 35

Table 17: Each Years Individual and Rolling Nominal Average Annual Energy Yield......... 35

Table 18: Indicative budgetary estimate for capital cost ..................................................... 41

Table 19: Project key indicators ......................................................................................... 44


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Glossary of Terms

A Amp

AC Alternating Current

ACB Air Circuit Breaker

ASHRAE American Society of Heating, Refrigerating and AirConditioning Engineers

CMS Central Monitoring Station

CRGO Cold Rolled Grain Oriented

c-Si Crystalline Silicon

C Degrees Centigrade

Degrees

DC Direct Current

EDO Electrically Draw Out

E EastGETCO Gujarat Energy Transmission Corporation Limited

GWh Giga Watt hour

HV High Voltage

Hz Frequency, Hertz

IAM Incidence Angle Modifier

Isc Short Circuit Current

IEC International Electrotechnical Commission

IP52 Limited dust ingress protection

kA One Thousand Amps

km One metric kilometer

kV One thousand Volts

kVA One thousand Volt Amps

kWp One thousand Watts peak

kWh One thousand Watt hours

LV Low Voltage

m Meters

m Meters squaredmm Millimeters

mm2 Millimeters squared

m/s Meters per second

MCCB Moulded Case Circuit Breaker

MPP Maximum Power Point


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1 INTRODUCTION

SunBorne Energy Services India Private Limited (SESPL) is a subsidiary company ofSunBorne Energy Holdings LLC. SunBorne intends to develop 1000MW of utility scale gridinteractive solar thermal (CSP) and solar photovoltaic (SPV) power projects in India.

Sunborne Energy is supported by US based private equity firms General Catalyst Partners

and Khosla Ventures; both these companies is understood to have rich experience in cleantech and renewable energy funding.

SgurrEnergy India was commissioned by SESPL to conduct a technical feasibility study andpreparing a detailed project report for a 15MW solar PV power plant under implementationat Karmaria village in the district of Bachau, Gujarat. The project shall be developed bySunborne Energy Engineering and Construction Limited as a turnkey contractors.

Consequently, in preparing the feasibility study, SgurrEnergy has made use of informationprovided by client and the data collected during a site visit by SgurrEnergy India personnelon 05 January 2011.

This report assesses project site, resource available and provides a draft plant design withproject components proposed by client, long term energy prediction. It describes:

Site features. The available solar resource.

Plant layout.

Nominal Annual energy predictions.

Electrical connection and equipment.

Control and monitoring options.

Others including site security.

The report also assesses the indicative budgetary estimates, financial model and projectimplementation schedule provided by client along with a review on power purchase

agreement.

2 SITE OVERVIEW

The Karmaria 15MW solar PV plant site lies around the co-ordinates N 23 20.960, E 7023.223, about 2km from village Karmaria and 253km from the city of Ahmadabad, acommercial city in the Indian state of Gujarat. Figure 1 illustrates location of site. It issituated at an altitude of approximately 28m, above mean sea level.

SunBorne Energy has acquired 104 acres of land, which is sufficient to develop a 15MW PVplant with crystalline solar PV technology. The description below is based on a desktopanalysis with the information provided by client and collected during the site visit. Thefeasibility and risks associated with developing a plant here are discussed in this report.


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Figure 1: Location of the Proposed Site at Karmaria

3 PROPOSED PLANT OVERVIEW

The proposed PV plant makes use of manual seasonal tracking to maximise the totalannual incident solar irradiation. It faces south orientation with a summer (April toSeptember) tilt1of 8 and winter (October to March) tilt1. of 38.

The PV modules selected by client, are of poly-crystalline type and are electricallyconnected with cables sized to minimise DC ohmic losses. The DC electrical output fromthe PV modules is fed via cables to string monitor boxes leading to inverter. The invertersconvert the DC electrical output to AC at 360V.

The cable routes from inverter leads to MV transformers stepping up voltage to 11kV. Thisvoltage further steps up for power evacuation at 66kV leading to main substation owned andoperated by Gujarat Energy Transmission Corporation Ltd. (GETCO). The metering pointfor the evacuated power shall be within the plant location at 66kV.

The PV module support structures selected and designed by SunBorne Energy shall belocally fabricated. Each table consists of a single row of 24 modules and have spaced tominimise the effect of inter row shading.

Table 1: Summary of Karmaria PV Power Plant gives the summary of plant components

selected by client; these are described further in sections to follow.

1This angle may be refined in the detailed design phase to maximise yield.

Karmaria


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Table 1: Summary of Karmaria PV Power Plant

Karmaria: Plant Summary

Nominal location 23 20.960 N, 70 23.223 E

PV module SolarWorld-SW230

PV Module peak power (Wp) 230

Modules per plant 68,960

Modules per plot 3,720

Strings per plot 155

Inverters SMA SC 800CP-10

Inverters per plot 1

Plots per plant 18

Inverters per plant 18

Mounting structure Locally fabricated

Mounting structure length per plot (m) 3831.6

Mounting structure length per plant (m) 68969

Peak power per plot (kWp) 855.60

Peak power per plant (MWp) 15.401

4 SITE DESCRIPTION

SgurrEnergy assessed the suitability of the site by undertaking a site visit along with clientrepresentatives, by assessing data received from the client, and obtained from a variety ofsources including satellite derived solar resource data. The site is described in the followingsections and issues regarding developing a 15MW solar PV power plant.

4.1 LAND TOPOGRAPHY AND CONDITION

An aerial view of the site area is illustrated in Figure 2. Photographs and the informationcollected during the site visit were used to analyse the topography and condition.

Site preparation and land development is in advance stage with land levelling completed forthe first 5MW of solar PV plant. Figure 3 illustrates the flat land developed for the PV plantwith a slight south tilt facilitating enhanced plant performance.


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Figure 2: Aerial view of the Proposed Site at Karmaria

Figure 3: Land Developed for Karmaria PV plant


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4.2 ACCESS

Figure 4: Access road to the site

Karmaria site is well connected by a three meter wide internal road. Condition of the road isgood and suitable for transportation of heavy vehicles required during construction. Nationalhighway 8A passes by approximately 10km from the site.

4.3 GEOTECHNICAL CONDITIONS

Preliminary geotechnical study was carried on the Karmaria site. The results indicate stratato be hard and compact clayey sand, having considerable gravel content.

Preliminary hydro geological investigations have shown a high water table in the solar PVsite, at around 2.0m from natural ground level. This groundwater is saline and is yet to betested for its chemical characteristics. This may restrict the depth of mounting structurefoundations below 1.5m for ease of construction.

Due to close proximity of the site to the sea shore there may be moist and saline currents ofair flowing hence appropriate measures to protect the modules and mounting structure fromcorrosion are required to be taken.

Preliminary Geotechnical report is attached in Appendix 8.

4.4 WATER AVAILABILITY

To maintain maximum efficiency, plant will require cleaning during long dry spells. Cleaningmay require large quantities of water depending on the manual labour available and degreeof soiling.

Water for construction and for cleaning modules as part of the O&M strategy may bedelivered by either of the following:

It is understood from the site visit that water is made available by tankers from thenearby village and stored in reservoirs.

Seasonal water reservoirs can also be evaluated as an option to fulfil waterrequirements of the plant. However, the rain fall in the proposed site area is veryscanty and understood to be only for a few months every year.


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Water can be sourced from bore wells; however, ground water availability and itssuitability on site and in the vicinity need to be investigated by professional experts.

For any of the source of water, SgurrEnergy recommends appropriate water quality testsand corresponding treatments for any adverse affect on modules.

4.5 ELECTRICAL INFRASTRUCTURE

SgurrEnergy understands the client to have applied for a 100kVA construction substation tothe distribution utility. Citing the power availability, a 40kVA diesel generator set may beserved as a standby source. These sources can be looked upon for serving as an auxiliarysupply system upon completion of project construction.

GETCO is understood to have conducted a power evacuation prefeasibility study and will beproviding transmission line from 66kV substation upto the PV plant. The 66kV substation islocated at approximately 8km from the site at village Sikra. The substation will be ownedand operated by GETCO.

The point of interconnection will be at the solar PV plant premises.

4.6 HORIZON SHADING

Horizon shading is the shading caused by land topography and objects located at asubstantial distance (e.g. mountains, etc.). Information from the site visit and satelliteimagery shows that there are no major mountains in the vicinity and therefore horizonshading is expected to be negligible.

Figure 5:Panoramic view from NE to NW showing horizon of Karmaria PV plant

4.7 SHADING FROM OBSTACLES

Installation of PV arrays in areas of potential shading is generally avoided as shading leadsto reduced performance. The site does not have any large nearby structures such asbuildings that may shade it. Nearby shrubs and trees may have to be removed.

Simulations indicate that the plant suffers 3.4% loss in winter and 0.2% in summer. This isdue to shading between rows of modules and control rooms in the morning and eveningwhen the sun is low.

4.8 CLIMATE

4.8.1 WIND

For the nominal energy prediction the METEONORM wind speed data shown in Table 2 isused. For wind loading analysis wind zone map in Appendix 2 is used, which indicates thatthe site is in high damage risk zone, having a maximum wind speed between 44 to 47 m/s.


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Table 2: Simulated Wind Speed at Karmaria site

MonthAverage Wind Speed at Ground Level (m/s)

METEORNORM Data

January 1.30

February 1.60

March 2.00

April 3.00

May 4.10

June 4.40

July 4.20

August 3.70

September 2.60

October 1.30

November 1.10

December 1.10

Annual Average 2.5

4.8.2 TEMPERATURE

SgurrEnergy has sourced average monthly temperature data from the METEONORMsoftware database. This data, shown in Table 3, is based on a nine-year period.

PV modules suffer from a decrease in efficiency with rise in temperature. The temperatureconditions experienced on site means that loss due to temperature may be relatively highcompared to sites in more temperate zones.

Table 3: METEONORM 6 Temperature Data for Karmaria site. (1996 2005)

Months Average Monthly Temperature (C)

January 19.00

February 22.10

March 27.40

April 30.50

May 31.80

June 31.60

July 29.70

August 28.60

September 29.10October 29.30

November 25.00

December 20.40

Annual Average 27


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4.8.3 PRECIPITATION

SgurrEnergy has simulated rainfall figures using METEONORM as shown in Figure 6:METEONORM Predicted Precipitation for Karmaria site. These show that the identified siteis situated in a region that has long periods with very limited rainfall. The effect of soiling onthe energy prediction should be assessed and a cleaning strategy chosen according to thebest economic returns.

Figure 6: METEONORM Predicted Precipitation for Karmaria site.

4.8.4 SOLAR RESOURCE

The annual energy prediction of a PV plant is heavily dependent on the solar resource ofthe site. SgurrEnergy understand a weather station has been commissioned on site inNovember 2010. The duration of recorded data is just for a month, it is thus necessary touse other data sources to obtain estimates of the solar resource.

4.8.4.1 AVAILABILITY OF RESOURCE DATA

There are a variety of possible solar irradiation data sources that may be accessed. Thedatasets either make use of ground based measurements at well controlled meteorologicalstations or use processed satellite imagery.

SgurrEnergy has sourced monthly horizontal plane irradiation data for proposed site from

the below mentioned sources. A brief description of the source data is also provided. NASA's Surface Meteorology and Solar Energy data set; holds satellite derived

monthly data for a grid of 1x1 covering the globe for a twenty-two year period (1984-2005). The data are suitable for feasibility studies of solar energy projects.

SWERA; obtains primary inputs into its models from geostationary satellites. Thesatellites provide information on the reflection of the earth-atmosphere system and thesurface and atmosphere temperature, which is useful in determining cloud cover.SWERA also uses data such as elevation, ozone, water vapour, snow cover, etc. toattain results. Model outputs are verified with ground-based data to ensure quality ofthe measurements.

The METEONORM global climatological database and synthetic weather generator;

contains a database of ground station measurements of irradiation and temperature.Where a site is over 20km from the nearest measurement station it outputsclimatologic averages estimated using interpolation algorithms. Where no radiationmeasurement station is within 300km from the site, satellite information is used. If thesite is between 50 and 300km from a measurement station, a mixture of ground andsatellite information is used. The accuracy of irradiation figures close to measurementstations are within a few percent. The interpolated global irradiation figures for India


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SgurrEnergy India

10/60XX/001/PUN/O/R/001

are given with an uncdistance between themountainous terrain.

Correlation to the resource dfrom satellite imagery.

4.8.4.2 ANNUAL HORIZONTA

SgurrEnergy has comparedNASA for the Karmaria sitemeasurements at the site, it i

The proposed site is apMeteorological OrganisationAppendix 2. For Karmariinterpolates from are Ahmed

The SWERA data illustrate22km (aerial distance) froexclusively for India, ratheran extensive list of SWERA

Indian boundaries. The resulSince temperature dataMETEONORM as the datamodeling, METEONORM prof ground and satellite meas

The METEONORM data mawhich is obtained purely froenergy prediction, the data i

Figure 8 illustrates the ratio

Figure 7: Mean Glo

2Quality of METEONORM Ver

0.00

1.00

2.00

3.00

4.00

5.00

.00

.00

.00

Karmaria 15MW PV Plant: Draft Det

Revision B2

rtainty of 7.5%2 for yearly values. Uncertaintsite and the measurement station, especi

ata may be done during detailed designs with

L IRRADIATION FOR KARMARIA SITE

the irradiation figures given by METEONOR. The data is shown graphically in Figure 7.impossible to say which source is most represe

proximately 240km from Ahmedabad; the(WMO) approved terrestrial measurement sta

site, the three nearest stations METEO abad (240km), Bhaunagar (264km) and Karach

in Figure 6 has been obtained for a locatiothe proposed site. SWERA data however,

for neighboring countries. SgurrEnergy perfordatasets to obtain appropriate coordinates t

ts give only irradiation data without temperaturis crucial for system design, SgurrEnergsource over SWERA. Due to this uncertai

ves to be the most representative as it providured data.

y therefore be slightly superior to the NASA asatellite data. SgurrEnergy uses the METE

shown in Table 4.

f direct and diffuse irradiation expected throug

bal Daily Irradiation on a Horizontal Plane for Karmari

sion 6.0, Jan Remund, World Renewable Energy C

iled Project Report

Page 18 of 59

y increases withlly in hilly and

datasets derived

M, SWERA andWithout ground

ntative.

nearest Worldion as shown inORM software

i (377km).

n approximatelyis not available

med iteration onat lie within the

e and wind data.y has choseninty in resources a combination

nd SWERA dataNORM data for

the year.

a site

ongress


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SgurrEnergy India

10/60XX/001/PUN/O/R/001

Table 4: METEONO

Month

January

February

March

April

May

June

July

August

September

October

November

December

Annual Mean

Figure 8: Direct and

Figure 9 compares the totafigures for PV power plantspredictions. It can be seeapproximately 22% higher thmonitoring programme or dsimulations.

0.00

1.00

2.00

3.00

4.00

5.00

.00

.00

.00


Revision B2

M 6 Irradiation Data for Karmaria, 1981-2000

Mean global daily irradiation on a horizontal plakWh/m

2

4.51

5.35

6.26

6.84

7.06

6.10

4.61

4.46

5.42

5.26

4.54

4.10

5.37

Diffuse Daily Irradiation on a Horizontal Plane for Kar

l annual global horizontal irradiation figures fin Spain on which SgurrEnergy has carriedthat solar resource simulations for the K

an similar simulations for the Spanish plants.etailed satellite derived study may be useful

iled Project Report

Page 19 of 59

e

maria

r Karmaria without energy yieldrmaria site aresolar irradiation

o confirm these


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10/60XX/001/PUN/O/R/001

Figure 9: Compari

5 PV PLANT COMPONThis section describes the mclient for plant design configby client are solar PV moduland data acquisition systemthese components.

5.1 PVMODULES

SolarWorld SW230 moduleoutput of 230Wp. The moduin Table 5.

The SolarWorld modules belthe solar industry for more tTUV certified. The mechaniwhich is well above the wind

SgurrEnergy understands fr61701 have been performedrelative humidity due to clos

SgurrEnergy has reviewed tthe conditions encountered

The industry standard modulend of 11 year at minimuprovides a linear performanof 10thyear, which is compar

0

200

400

00

00

1000

1200

1400

100

100

2000

2200

1

()


Revision B2

on of Solar Resource for Karmaria and PV Plants in

NTSain components of the PV plant that have beeuration in preparing this report. The main com

s, inverters, junction boxes, mounting structur. SgurrEnergy has reviewed the technical sp

selected by client are polycrystalline modulle specifications are shown in the Appendix 2

ong to Tier 1 class of modules. SolarWorld haan 30 years. The modules are qualified to IE

ical load bearing capacity of SolarWorld mogust speed likely to be encountered on the site

om the certificate provided by client that interfor SolarWorld module for no effect due to saltvicinity to sea.

e module specifications. They are consideredt the site.

e power warranty is 80% at the end of 25 year power output or at nominal power of mo

e guarantee of 93% for 25 years resulting in 8atively higher compared to normal industry sta

2 3

iled Project Report

Page 20 of 59

pain

selected by theonentsselectedand monitoring

cifications of all

les with a ratedand summarized

the presence in61215 and are

ule is 5.4kN/m2.

al tests for IECmist and excess

o be suitable for

and 90% at theule. SolarWorld9.3% at the enddard.


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Table 5: PV Module Specifications

PV Module SolarWorld-SW230

Type Poly silicon

Max. output, Pmax, at STC (W) 230

Maximum power voltage, Vmpp(Volts) 29.8Maximum power current, Impp(A) 7.72

Open-circuit voltage, Voc(V) 36.9

Short-circuit current, Isc(A) 8.25

Length (mm) 1675

Width (mm) 1001

Thickness (mm) 31

Weight (kg) 22

5.2 MODULE STRING/ARRAY CONFIGURATION

The plant is designed such that each inverter is connected to 155 strings of twenty fourmodules connected in series. This arrangement ensures the current and voltage levelsmatch the specification of the inverters. The configuration is summarised in Table 7.

The system design parameters are as shown in Table 6.

Table 6: PV Module Configuration

Module peak power (Wp) 230

Modules per string 24

Strings per inverter 155

Modules per inverter 3720

Modules per mounting structure 24

Modules per plant 66,960

Table 7: System Design Parameters


Modules per string 24

Strings per inverter 155

Inverter Max Power, Pmax, at STC (kW) 855.6

Maximum power voltage, Vmpp (Volts) 715.20

Maximum power current, Impp (A) 1196.6

Open-circuit voltage, Voc, (V) 885.6

Short-circuit current, Isc (A) 1278.75


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5.3 INVERTERS

The DC electricity generated by the modules is converted to AC in the inverters. The designuses SMA make SC 800CP-10 transformerless inverters, as selected by the client.SgurrEnergy has reviewed the specifications inverters and finds suitable for the project.These are three phase inverters with compact and weatherproof enclosures. Each modularplot shall have a separate inverter.

As per industry standard, inverter manufacturers provide 5 year standard warranty withoptional 10 year extended warranty which may be obtained by developer as a part of O&M.

Table 9 below summarises some important characteristics of the inverter considered fordesigns.

Table 8: Inverter Specifications

Inverter SC 800CP-10

Max. DC voltage 1000 V

PV voltage range, MPPT 570 - 820 V

Max. input current 1,400

Number of MPP trackers 1

Max. number of strings (parallel) 9

Nominal AC output 800,000 VA

Max. output current 1411 A

Nominal AC voltage / range 360 V 10%

AC grid frequency 50 Hz

Max. efficiency 0.986

Euro ETA 0.984

Normal Ambient temperature range 20 C ... +50 C

Maximum ambient temperature +50 C

Consumption: operating (standby) / night < 1500W / 100W

Warranty 5 years

Optimal operation of the considered inverters occurs below 40C. Due to the relatively hightemperature conditions that may be encountered at the site, care should be taken that theinverters are shaded, well ventilated and situated sufficiently far enough apart to ensure thatthey do not take in the cooling air of the neighbouring unit. The temperature data which hasbeen accessed indicates that it is unlikely that the ambient temperature will often exceed40C. With the precautions mentioned above, the inverters inbuilt SMA OptiCool system isexpected to cope with the temperatures experienced on site. However, SgurrEnergyrecommends that site temperature data should be verified to ensure that temperatures

above 40C do not cause unacceptable annual energy yield loss.In order to reduce AC cable runs, inverters shall be placed at the centre of each plot.

Table 9 summarises the system configuration with respect to the inverter setup.


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Table 9: Inverter Summary

Nominal output power (kW) 800

Inverters per plot 1

Inverters per plant 18

Modules per string 24Strings per inverter 155

5.4 MODULE SUPPORT STRUCTURES

Details provided by client indicate locally fabricated mounting structures will be used for thisproject.

According to India wind zone map provided in Appendix 2, Karmaria lies in high damagerisk zone with maximum wind speed in the range of 44 to 47 m/s. The mounting structuresare understood to be designed for withstanding the wind speed of 180km/hr (50m/s) whichexceeds the upper limit of the maximum wind speed range.

Mounting structure with manual seasonal tracking, south facing orientation, tilted 8 from the

horizontal in summer (April to September) and 38 from the horizontal in winter (October toMarch) has been chosen by the client to maximise the total annual incident solar irradiation.

The modules will be arranged in portrait orientation with a single row. Twenty four modulesare assembled per 24.72m length of support structure. Figure 10 and Figure 11 shows anindicative schematic drawing and inter row spacing for the support structure for tilt of 8 insummer and 38in winter respectively. To accommodate the 66,960 modules approximately68,355m of support structure are needed.

Figure 10: Indicative layout of Inter row spacing at 8tilt in summer

Figure 11: Indicative layout of Inter row spacing at 38tilt in winter


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Table 10: Mounting Structure Summary

Modules per 24.72m length of mounting structure 24

Number of 24.72m mounting structures per plot 155

5.5 SITE SECURITY

In order to reduce the risk of theft and tampering, installation of a security fence for the siteboundaries is in progress as can be illustrated from Figure 12. Galvanized and plastifiedfencing with 70g Zn/m2 is commonly used for this type of plant. For environmentalpurposes, measures should be taken to allow small animals to pass underneath.

Security cameras are sometimes specified for PV plants as shown in Figure 13 . Securitycameras may be considered as an option for vigilance.

Figure 12: Site Fencing In Progress


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Figure 13: Example of Security Systems used in PV Power Plants

5.6 REMOTE MONITORING AND DATA ACQUISITION SYSTEM

For large solar plants, a variety of components can be assembled to create a customisedmonitoring solution. A perfectly co-ordinated system benefits both the installer and gridoperator. The monitoring and data acquisition system chosen by client are the standardproducts of SMA and are normally customized in conjunction with SMA inverters.

The power plant incorporates a communication system to monitor the output of each stringcombiner box and inverter so that system faults can be detected and rectified before theyhave an appreciable effect on production. The monitoring system will be a web basedinternet portal solution. The project uses SMA SSM24-11 string combiner boxes, controlsand instrumentation and SCADA system. The monitoring system will be a web basedinternet portal solution.

Typical schematic of the monitoring system architecture is indicated in Figure14


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Figure 14: Indicative schematic of data monitoring

Monitoring system includes the following elements:

SMA Sunny String-Monitor 24 SMA Sunny WebBox SMA Sunny Central Control SMA Sunny SensorBox

The Sunny String-Monitor measures and compares the individual string currents in order todetect power deviations and therefore anomalies. Each Sunny String-Monitor allows theconnection of up to 24 strings. The specifications of the Sunny String-Monitor are given inTable 11. It can be delivered in an enclosure for wall mounting or as a standalone box.

Table 11: Specifications of the SMA Sunny String-Monitor 24 (SSM24-11)

Maximum permissible DC voltage 1000V

Maximum permissible DC current 320A

Number of measuring channels 24

Maximum string current per measuring

channel13.30

Dimensions (mm) 1060x1085x245

Weight (kg) 80

Operating temperature range -25 to +40C

Relative humidity 15 to 95%


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The Sunny String-Monitor boxes are then connected to the Sunny Central Control viaRS485 cables. The Sunny Central Control enables detailed recording and analysis of thedata monitored by each Sunny String-Monitor.

Installed indoor, the SMA Sunny WebBox is a data logger that continuously monitors up to50 devices in real time and automatically reports system status. All performance data of theplant (e.g. inverter, plant power production) is recorded and exported for evaluation. Inverter

parameters can also be centrally adjusted from the WebBox. Data can be accessed fromany computer with an internet connection so that operational failures can be detected at anearly stage. The WebBox and the Central Control devices communicate with each other viaEthernet. Specifications of the Sunny WebBox are presented in Table 12.

Table 12: Specifications of the SMA Sunny WebBox

Communication to Sunny Central Control 10/100 Mbit Ethernet

Maximum communication range 100m

Maximum number of SMA devices 50


Weight (g) 750

Plug-in power supply 100-240V, 50/60Hz

Power consumption Typ. 4W / Max. 12W

Ambient temperature -20 to +65C

Relative air humidity 5 to 95%, non-condensing

Additionally, SgurrEnergy recommends the use of an SMA Sunny SensorBox to monitorenvironmental conditions at the PV plant. Installed outdoors on a PV module, theSensorBox measures the solar irradiation and module temperature using a solar cell and

temperature sensor. The actual measured output of the inverters can then be comparedwith the expected output calculated from the solar resource. This allows the identification ofsystem failures3. The SensorBox is also connected to the WebBox via a RS485 dataconnection. The specifications for the Sunny SensorBox are shown in Table 13.

Table 13: Specifications of the SMA Sunny SensorBox

Communication to the datalogger (Sunny WebBox)

RS485

Maximum communicationrange

1200m

Solar irradiation Range 0-1500W/m

2

(Precision 8%)Module temperature Range -20C to +110C (Precision 0.5C)

Ambient temperature Range -30C to +80C (Precision 0.5C)

Wind measurement Range 0.8-40m/s (max 60m/s short term) (Precision 0.5m/s)

3 Additional sensors may also measure the ambient temperature and wind speed for more precisecalculations.


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Power supplyVia RS485 line; via external power supply (indoor power

injector); max 150m cable


Weight (g) 500

5.7 PVPOWER TRANSFERThe 15 MW PV plant has been divided in eighteen independent bus sections at the lowvoltage (LV) level. Each plot output shall be stepped up to 11kV using 1000kVA outdoortype transformer. These shall be appropriately combined and stepped up to 66kV usingthree 6.25MVA ONAN outdoor type transformers located at PV plant premises. Three 66kVlines from the transformers will form into a single bus and power will be transferred to theGujarat Energy Transmission Company Ltd. (GETCO) substation at village Sikra locatedapproximately 8km from the plant.

The metering point for the power evacuation shall be at the power plant premises onoutgoing 66kV lines; further transmission and related infrastructure will be provided by theGETCO.

5.8 CIVIL STRUCTURESAn appropriate structure to provide security and shelter to the low voltage transformers andelectrical panels will be needed. The structure shall be constructed from eitherbrickwork/blockwork with a concrete or steel sheeted roof. The building has been placed atcentre of plot module to minimise cable losses.

5.9 CABLING

All the DC and AC cables are designed for outdoor application with a continuous ambienttemperature of 50C. They are sized for a power loss below 2.35% and a voltage drop lessthan 2%.

5.9.1 DCCABLING

All the modules shall be equipped with attached junction boxes with 4mm2connecting leads.Modules will be interconnected to form a string of twenty four modules using these leads,further single core; 16mm2multi-stranded copper cables connects each string to the stringcombiner box (SCB). These cables will be cross linked polyethylene insulated andtemperature & UV resistant.

Further the power from such SCBs is taken to inverter located within the plot. These cableswill be cross linked polyethylene insulated and temperature resistant.

5.9.2 ACCABLING

The three phase AC output from each of the inverter of a plot will be connected to the Aircircuit breaker using 2 runs single core, 630mm2 copper cables per phase. Further to this1600A, TPN Aluminium sandwich type bus duct will connect to LV winding of 1000kVA

transformer for stepping up the voltage to 11kV located centrally in the plot.

Power will be fed from the high voltage side of each transformer through 3 core, 120mm2,11 kV XLPE insulated aluminium cable to the sub main MV Switchboard. These sub mainMV switchboard shall be suitably combined with 3 core, 185mm2, 11 kV XLPE insulatedaluminium cable for the power to be further stepped up to 66kV at the power plant premises.Designs of this switchyard and step up substation will be done in the detailed design phase.


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These air terminals will be connected to respective earthing stations, and an earthing gridwill be formed connecting all the earthing stations through the required galvanised irontapes.

The earthing stations for the lighting discharges will be provided with test links ofphosphorus bronze and located at 150mm above ground level in an easily accessibleposition for testing.

5.15 GRID CONNECTION

Power shall be evacuated at 66kV level at the Sikra transmission substation owned andoperated by GETCO and located approximately 8 km from site. The point of interconnectionat 66kV level will be at plant location, further electrical infrastructure will be provided byGETCO.

5.16 SUMMARY OF SYSTEM CHARACTERISTICS

5.16.1 ACHIGH VOLTAGE SYSTEM

Rated voltage: 66kV.

Number of phases: 3.

Nominal frequency: 50Hz.

5.16.2 ACMEDIUM VOLTAGE SYSTEM

Rated voltage: 11kV.

Number of phases: 3.

Nominal frequency: 50Hz.

5.16.3 ACLOW VOLTAGE SYSTEM

Operating voltage: 360V.

Number of phases: 3 Nominal frequency: 50Hz.

5.16.4 DCSYSTEM

Operating voltage inverters: 570V 820V.

Maximum system voltage: 1000V.

5.16.5 SERVICE CONDITIONS

Ambient temperature range: up to 45C.

6 PLANT DESIGN

6.1 PLANT LAYOUT

As space is not a major constraint at the location chosen, the layout of the 15MW plant ischosen to maximise the annual energy output. Further layout refinements may be made inthe detailed design phase.

The distance between rows of mounting structures has been chosen such that there isminimal inter-row shading at the maximum sun angle on the winter solstice and adequatedistance for maintenance purposes. Figure 14 shows an indicative layout for 15MW PV


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plant. The layout is designed with a pitch (distance between the fronts of one row to thefront of the next row) of 4.5m.

7 REQUIREMENTS FOR DEVELOPING AND MAINTAINING A PV POWER PLANT

In order to establish and maintain a solar PV plant there are a number of requirementswhich are discussed below.

7.1 SITE ESTABLISHMENT

Workforce: Accommodation for the workforce required for construction may be found invillages located near the site.

Fuel:The nearest petrol/diesel refueling station for construction vehicles is approximately5km from the site. A temporary fuel reserve of around 200 liters may also be stored in tanksif required.

Electricity: Power requirement during project construction may be catered from a 40kVAdiesel generator set as standby source.

Construction substation of 100kVA can be installed for powering site establishment andconstruction activities. The availability of continuous power from power utility is quite

unknown as of now; hence backup of 40kVA diesel generator can be maintained as astandby source for smooth project execution.

7.2 MAINTENANCE REQUIREMENTS

The energy output of the plant will be monitored using the remote data acquisition systemconnected to each inverter as described in earlier section. Significant reduction in energyoutput will trigger specific maintenance requirements, such as inverter servicing or modulereplacement. In addition to this, on-going maintenance of the plant may be required andtypical activities are as described below:

Modules: Visual inspection and replacement of damaged modules will be required atregular intervals. Cleaning of the module glass surface during long dry periods may beconsidered. Cleaning may be conducted using a tucker pole (a long hollow pole with a hose

fitting on one end and a soft bristle brush on the other). Alternatively automatic watersprinkling system with underground storage and pumping may also be used.

General maintenance: Vegetation will need to be cut back if it starts to cause a fire risk orintroduce shading.

Module support structure:Annual visual inspection for general integrity of the structure,corrosion, damage and fatigue. All frame connections should be checked for deflections ortears at the module and cross beams to assess the need for replacement.

Wiring and junction boxes:Visual inspection for corrosion, damage such as chafing, anddamage by rodents and birds, and for overheating of cables and connections. This requiresthe skills of an electrical technician.

Inverters: Inverter maintenance requires the skills of an electrical technician. It involves:visual inspection of the fans, tightening leads and cleaning using a vacuum cleaner orbrush.

Safety devices:Checking connections, functionality of isolators and circuit breakers, andfor signs of overheating.

Security system: Visual inspection for damage and breaches in the security fence.


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8 NOMINAL ENERGY PREDICTION

SgurrEnergy has predicted nominal annual energy output from the Karmaria PV site usingclients design for 15MW plant and layout as described in Section 6. SgurrEnergy have:

1) Sourced average monthly horizontal irradiation, wind speed and temperature datafrom a variety of sources including satellite image derived data and data from landbased meteorological stations as described in Section 4.8. These data have beenassessed and judiciously selected for use in the energy prediction simulation software.

2) Calculated the global incident radiation on the tilted collector plane with seasonaltracking taking into account shading.

3) Calculated the losses, as described in detail in the Appendix 1, using details of theinverter specifications, PV module specifications, site layout and characteristics.

4) Applied ohmic losses, and transformer losses to obtain an energy prediction thatreflects a twenty five year plant life.

Steps 2 and 3 are facilitated using industry standard photovoltaic simulation software whichsimulates the energy prediction using hourly time steps. The software takes as inputdetailed specifications of:

The solar PV modules. The inverter.

The site layout, including a 3D representation of surrounding shading structures if anyare present.

Electrical configuration including number of modules in series and parallel.

8.1 RADIATION IN THE PLANE OF THE MODULES

The annual global irradiation incident on the collector plane has been maximised by tiltingthe modules at an angle4of 38 to the horizontal during winter (October to March) and at anangle of 8 for summer (April to September). PV modelling software is used to calculate theincident global irradiation in the tilted collector plane from the irradiation in the horizontal

plane.

8.2 CORRECTIONS AND LOSSES

Using the calculation of the irradiation in the collector plane and knowledge of the PVmodule specifications and configuration, PV modelling software is used to calculate the DCelectricity generated from the modules in hourly time steps throughout the year. This directcurrent is converted to AC in the inverter.

A number of losses occur during the process of converting irradiated solar energy into ACelectricity fed into the grid. The losses may be described as a yield loss factor. These lossesare calculated within the PV modelling software, calculated from the cable dimensions andfrom information gathered during the site visit. Others are nominal figures applied fromknowledge of performance of similar PV plants. The losses are summarised in Table 14and

described in more detail in Appendix 1.

4This angle may be refined in the detailed design phase according to the precise solar resource.


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Table 14: Description of Energy Prediction Losses

Loss Description

Shading Three types of shading losses are considered in the PV energyprediction model: horizon shading, shading between rows of modulesand near shading due to trees and buildings.

Incident angle The incidence angle loss accounts for losses in radiation penetrating thefront glass of the PV modules due to angles of incidence other thanperpendicular.

Low irradiance The conversion efficiency of a PV module reduces at low lightintensities.

Module temperature The characteristics of a PV module are determined at standardtemperature conditions of 25C. For every C temperature rise abovethis, crystalline silicon modules reduce in efficiency, generally by around0.45%.

Soiling Losses due to dust and bird droppings soiling the module.

Module quality Most PV modules do not match exactly the manufacturers nominalspecifications. Modules are sold with a nominal peak power and a given

tolerance within which the actual power is guaranteed to lie.

Module mismatch Losses due to "mismatch" are related to the fact that the real modules inan array do not all rigorously present the same current/voltage profiles:there is a statistical variation between them.

DC wiring resistance Electrical resistance in the wires between the power available at themodules and at the terminals of the array gives rise to ohmic losses(IR).

Inverter performance Inverters convert from DC into AC with a maximum efficiency.Depending on the inverter load, they will not always operate atmaximum efficiency.

AC losses This includes transformer performance (MV/HV) and ohmic losses in thecable leading to the substation.

Downtime Downtime depends on the grid availability, diagnostic response time,stock of spare equipment and the repair response time.

Degradation The performance of a PV module decreases with time.

MPP tracking The inverters are constantly seeking the maximum power point (MPP) ofthe array by shifting inverter voltage to the maximum power pointvoltage. Different inverters do this with varying efficiency.

8.3 NOMINAL ENERGY PREDICTION

Table 15 below summarises the Karmaria solar PV power plant, the available resource, thelosses and the nominal energy prediction.

Table 16: First Year Nominal Energy Predictionshows the resource and monthly output.

Table 15: Nominal Energy Prediction for Karmaria PV Power Plant



Modules per plot 3,720

Peak power per plot (kWp) 855.6

Number of plots 18


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Table 15: Nominal Energy Prediction for Karmaria PV Power Plant


Module area per plot(m2) 6,237.2

Total Module Area (m2) 112,270

Peak power of plant (MWp) 15.401

Module efficiency at STC (%) 13.9%

Solar Resource (based on METEONORM data)For tilt of 8(Summer)

For tilt of38

(Winter)

Annual global horizontal irradiation (kWh/m ) 1,051 910Global irradiation incident on collector plane (kWh/m ) 1,048.90 1,161.50

Losses

Shading1 0.998 0.966

Incident angle 0.967 0.976

Low irradiance 0.956 0.970

Module temperature 0.872 0.876

Soiling 0.971 0.971

Module quality 0.984 0.984Module mismatch 0.986 0.986

DC ohmic 0.989 0.989

Inverter performance 0.984 0.984

Down time2 1 1

First Year Degradation 1 1

Total annual loss factor post inverter 0.738 0.735

First Year Energy Output at Inverter Output (GWh/annum)4 12.073 13.316

First Year Specific Output at Inverter Output (kWh/kWp) 784 865

AC losses

AC ohmic 0.988 0.988

Transformer LV/MV 0.985 0.985Transformer (MV/HV) 0.987 0.987

Total annual loss factor post transformer 0.708 0.705

First Year Energy Prediction after AC Losses (GWh/annum) 11.59 12.78

First Year AC Specific Prediction (kWh/kWp) 752.62 830.08

Total First Year Energy Prediction after AC Losses(GWh/annum)

24.37

Total First Year AC Specific Prediction (kWh/kWp) 1582.7

PLF5 18.54

Notes:1)Due to inter-row shading, horizon shading and shading from obstacles (if any).2) As per clients information loss due to grid non availability is taken to be negligible.3) Considering no degradation of module at the start of the year, first degradation is not taken into account.

4) Energy required by auxiliary services is not accounted for.

5PLF is calculated on 15MW AC installed capacity.


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Table 16: First Year Nominal Energy Prediction

MonthlySum GlobalHorizontalIrradiation(kWh/m2)

MonthlySum Global

InclinedIrradiation

at 22

(kWh/m2)

SpecificAC Output(kWh/kWp)

Proportionof Annual

Production

First YearAC Energy

Output(GWh)

Summer

April 205.2 208 148.89 9.42% 2.29

May 218.7 216 154.84 9.80% 2.38

June 182.9 179 128.65 8.14% 1.98

July 142.9 141 101.24 6.40% 1.56

August 138.4 138 99.09 6.27% 1.53

September 162.7 167 119.83 7.58% 1.85

Winter

October 139.9 188 134.64 8.52% 2.07

November 149.9 183 130.64 8.26% 2.01

December 194.2 188 134.50 8.51% 2.07

January 162.9 200 143.00 9.05% 2.20

February 136.1 191 136.36 8.63% 2.10

March 127.2 209 149.08 9.43% 2.30

Total 1961 2208 1581 100% 24.35

Table 17 shows each years individual and rolling average of nominal energy yields. Anannual degradation rate of 0.5% and 0.7% has been assumed.

Table 17: Each Years Individual and Rolling Nominal Average Annual Energy Yield

YearNominal Each Year's

individual Energy Yield6

(GWh/annum)

Rolling Average with0.5%

7annual Degradation(GWh/annum)

Rolling Average with 0.7%8

annual Degradation(GWh/annum)

1 24.126 24.126 24.126

2 24.006 24.066 24.042

3 23.886 24.006 23.958

4 23.766 23.946 23.874

5 23.647 23.886 23.791

6Nominal Energy Prediction with 1% degradation at the end of 1styear.7Comparison of Degradation Rates of Individual Modules Held at Maximum Power Technical paper presentedby US Department of Energy, National Renewable Energy Laboratory at the 2006 IEEE 4th World Conferenceheld on May 7-12, 2006,8According to the Solar World 25 year linear performance guarantee, which needs to be validated at the time ofpurchase


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Table 17: Each Years Individual and Rolling Nominal Average Annual Energy Yield

YearNominal Each Year's

individual Energy Yield6

(GWh/annum)

Rolling Average with0.5%

7annual Degradation(GWh/annum)

Rolling Average with 0.7%8

annual Degradation(GWh/annum)

6 23.529 23.827 23.708

7 23.411 23.767 23.626

8 23.294 23.708 23.543

9 23.178 23.649 23.462

10 23.062 23.591 23.380

11 22.947 23.532 23.299

12 22.832 23.474 23.219

13 22.718 23.416 23.139

14 22.604 23.358 23.059

15 22.491 23.300 22.979

16 22.379 23.242 22.900

17 22.267 23.185 22.821

18 22.156 23.128 22.743

19 22.045 23.071 22.665

20 21.935 23.014 22.587

21 21.825 22.957 22.510

22 21.716 22.901 22.433

23 21.607 22.845 22.357

24 21.499 22.789 22.280

25 21.392 22.733 22.204

8.4 CAPACITY FACTOR

The Capacity Factor (CF) also known as Plant Load Factor (PLF) of a PV power plant(usually expressed as a percentage) is the ratio of the actual output over a period of a yearand its output if it had operated at nominal power the entire year, as described in theformula below.

The CF for the first year of the Karmaria PV plant has been computed as 18.54% using theabove equation.

9 PERMITS AND LICENSING

Obtaining the relevant permits and licenses is essential to facilitate the timely completion ofa project and to ensure that the development proceeds in harmony with the naturalenvironment, existing land usage and other regulatory interests such as defence andaviation.


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9.1 PERMITTING,LICENSING AND CONTRACTUAL REQUIREMENTS

The key permits, licenses and contracts for the Karmaria PV plant acquired by clientinclude:

Land lease contract.

EIA.

Building permit/planning consent.

Renewable energy equipment supply agreement and warranty.

Grid Power for Evacuation.

Power purchase agreement.

The authorities, statutory bodies and stakeholders usually include the following generalorganisation types:

Local and/or regional planning authority.

Environmental agencies/departments.

Archaeological agencies/departments.

Civil aviation authorities.

Ministry of defence.

Local communities.

Health and safety agencies/departments.

Electricity utilities.

10 GUJARAT SOLAR POLICY AND TARIFF REGULATION

The Government of Gujarat released the solar power policy on 6 January, 2009 with the aimto generate clean energy using solar power, boost technology development within the stateand cater in beneficial use of wastelands. The policy will be operative until 31 March, 2014and the Solar Power Generators (SPGs) commissioned before this date can take advantageof the incentives declared under this policy for a period of 25 years or the life span of theproject, whichever is shorter.

The policy envisages total installation of 500MW and has limited the minimum andmaximum capacity for solar power projects at 5MW and 50MW respectively.

10.1 HIGHLIGHTS OF THE SOLAR POLICY &REGULATION

This section discusses the relevant highlights Gujarat solar policy and the solar tariff orderreleased by Gujarat electricity regulatory commission (GERC). Solar policy of Gujarat andthe tariff order are provided in appendix 4

Eligibility Criteria - Any company or body corporate or artificial judiciary person or body

of individuals (incorporated or not) will be eligible of setting up SPGs for captive use orfor sale of generated power in accordance with The Electricity Act 2003, as amendedfrom time to time. The entities must submit a detailed proposal to the Gujarat nodalagency to be considered for selection. However, prior to submitting the proposal theymust clear the required eligibility criteria.

Financial Criteria

i. The entity must have an Internal Resource Generation of INR 120 million orequivalent US $ per MW, which will be calculated as five times the maximuminternal resource generated during the last five years.


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ii. Should have a Net worth of INR 2 crore or equivalent US $ per MW in annualaccounts in any of the last three years.

iii. Should have an annual turnover of INR 480 million or equivalent US $ per MW inany of the last three years.

a. Technical criteria - The entity must have completed any project in the last 10 yearswith an aggregate capital cost of INR 30 million per MW of the capacity. Further, theentity must essentially have collaboration with a proven technology supplier of solarpower projects. Further, only new plant and machinery will be eligible for installationunder this policy.

Bank Guarantee - A bank guarantee of INR 5 million per MW will have to be provided atthe time of signing the Power Purchase Agreement (PPA) with the GUVNL or thedistribution licensee. The guarantee will be refunded if the developer achievescommercial operation within the time period specified at the time of signing the PPA.

Project Capital Cost For determining the levelised tariff the Gujarat ElectricityRegulatory Commission has decided upon a capital cost of INR 165 million, thisexcludes the electrical infrastructure cost further to interconnection point that shall beprovided by GETCO. Operations and maintenance cost has been benchmarked at 0.5%of the project capital cost, this amounts to INR 0.825 million.

Project Financing debt-equity ratio of 70:30 has been in accordance to electricity act.The commission notifies loan tenure of 10 years with an interest rate of 11.5%.

Sale of energy - The solar power generated can be sold at a levelised tariff of INR15/kWh for the first 12 years followed by INR 5/kWh from the 13 th to the 25th year.However rates will be decided by the Gujarat Urja Vikas Nigam Ltd (GUVNL) or theDistribution licensee for power purchase.

Duty Exemptions - The developers will be exempted from paying electricity duty anddemand cut (for captive use purpose) to the extent of 50% of the installed capacity.

Metering - Metering will be carried out monthly by Gujarat Energy Development Agency(GEDA) and Gujarat Energy Transmission Company Ltd (GETCO) at the substation of

66kV or higher. Grid Connectivity - The transmission line from the solar substation/switchyard to the

GETCO will be carried out by GETCO. GETCO will initially study the evacuation facilitybefore approval. The power will be injected at 66kV.

If open access is granted, the developer or beneficiary will have to pay the applicableopen access charges and losses as decided by the GERC.

Renewable Purchase Obligation - Renewable Purchase Obligation (RPO) will beapplicable to distribution licensees, captive consumption and third party sale. The RPOis decided as 5% for 2010 11 out of which 0.25% is from solar. The percentagecontribution from solar is envisaged to double every year until 2013.

A penalty of INR 12/kWh, payable to GEDA would be applicable if RPO is not met by the

distribution licensee. However, penalty will not be forced if there is non-availability dueto inadequate solar power generation in the state.

Support from Nodal Agencies - GEDA and Gujarat Power Corporation Ltd (GPCL) willbe the Nodal Agencies and help SPGs developers in identifying suitable land, obtainingclearances and approvals, promote R&D, etc.

Mid-Term Review - The state government will review the solar policy every 3 years or asthe need arises (due to advancement in technology, address changes in The ElectricityAct, etc.)


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Clean Development Mechanism (CDM) sharing - The developer will share 50% of thegross benefits of CDM with the distribution licensee for the first year, with whom the PPAwas signed. This shall proportionately reduce in subsequent years as illustrated inFigure 18.

11 PROJECT FINANCES

SgurrEnergy has assessed the financial model for the proposed Karmaria 15MW solar PVproject. Under the Gujarat solar policy, SunBorne Energy has signed PPA with Gujarat UrjaVikas Nigam Limited (GUVNL) hence, various project performance parameters aredependent on the tariff determined by Gujarat Electricity Regulatory Commission (GERC)and the capital cost. Project capital cost is primarily based on the budgetary estimatesprovided by SunBorne Energy that are availed through offers from various suppliers of PVplant components.

11.1 PROJECT COST ESTIMATES

This section indicates the project capital cost for the proposed Karmaria 15MW solar PVproject. Escalation within the prevailing prices for the construction period is not consideredas it is unlikely to increase the cost for various components.

Land -104 acres of land shall suffice for a 15MW solar power plant. This shall includeeighteen plot modular units, MV substation and HV switch yard.

Planning and Permissions - are the pre-operative expenses required to completeregistration process availing necessary approvals, preparing various assessmentreports, security deposits and processing fees to adhere relevant regulatoryrequirements etc. Apart from this the project shall also incur people cost for the variousproject development and administrative expenses of the project. This shall alsoincluded Engineering and Project Management services essentially including the costassociated starting from resource assessment, engineering designs, supervision rightthrough to project management and commissioning. This is a nominal expense andaccounts around 1% of the entire capital cost.

Figure 15: Project capital cost breakdown.

2%

5%

%

12%

1%

%

1%4%

1%3%

4%

&


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Infrastructure Development - over all infrastructure development for the site isessentially consists of land development, roads and public health development,electrical work during construction, air conditioning and ventilation, development ofadministrative, control rooms and other buildings, security systems such as fireprotection system, fencing, communication system and other. This accounts to less than2% of the capital cost in this estimate.

Civil Works - cost determined under this section is INR 8.52 million/MWp. This costincludes major civil foundation work at the plant site such as foundations for mountingstructure, LV & HV transformers, switchyard foundations and other civil work.

Solar PV Modules - PV module cost accounts to highest share of the capital cost, for theproposed project it has been estimated to 56% of the total capital cost. Module has beenselected on the basis of specific technology and capacity suitable is determined byassuming prevalent rate of USD 1.64/Wp.

Module Mounting Structures - cost considered for mounting structure is INR 25.46million/MWp. Cost of locally manufactured and fabricated structures accounts toapproximately 12% of the total capital cost.

Inverters - cost considered for Inverters along with the required controls and

instrumentation is INR 15.98 million/MW. Power Evacuation Infrastructure - This includes supply, erection and commissioning of

entire cabling, transformers and evacuation infrastructure 11kV/66kV transformersubstation, switchyard and metering necessary. The cost estimates to 8% of entirecapital cost.

Contingency provision of 3% has been considered for project. The capital intensivesolar power projects in India are considerably a new to implement. The contingencyprovision also supports to implementation of innovation within the project for improvingoverall efficiency of the project.

Interest during construction (IDC) since the investment is capital intensive in natureand project cost for the proposed multi megawatt size plant shall be higher. Interestduring the construction is considered for six months at the rate of 11% per annum. Thegestation period for the completion of 15MW power plant period is considered is sixmonths.

Table 18 presents an indicative budgetary estimate for the proposed Karmaria 15MW solarpower plant. This includes design, supply, installation, testing and commissioning of theentire plant along with the project development costs.


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Table 18: Indicative budgetary estimate for capital cost

BUDGETARY ESTIMATE FOR 15MW GRID INTERACTIVE SOLAR PV PROJECT

(Cost in million Indian Rupees)

S No. Description UnitQuantit

y

Unit

RateCost

1 Cost of Land and Site Development Lump sum 3.7 3.71

2 Modules MW 15 7.9 118.82

3 Inverters Nos. 18 0.9 15.98

4 Structures MW 15 1.7 25.46

5 Transformers Nos. 21 0.1 2.98

6 Switchyard Nos. 1 17.5 17.48

7 Miscellaneous 1.3 1.25

8 Civil Works Lump sum 8.5 8.52

9 Preliminary & Pre-operative Expenses Lump sum 1.2 1.210 Contingency Lump sum 5.7 5.7147

11 Margin Money and IDC Lump sum 9.2 9.20

Total 212.818

11.2 OPERATION AND MAINTENANCE COST

Operation and maintenance (O & M) expenses comprising spares, extended warranties,repairs, routine and preventive maintenance, insurance expenses, employee remunerationand administrative costs have been estimated at INR 0.825 million/MW for base year,subsequently there shall be an annual escalation of 5% over the tariff period. The escalationis attributed to take care of incremental cost in O & M for smooth functioning of plant.

Key highlights on O & M cost assumptions are mentioned below:

Project life - 25 years Annual escalation in O & M cost - 5% Mounting Structure - Fixed type.

Man powero Number of engineers 06o Number of technicians 08o Administration staff 06o Security staff 18o Managerial Staff - 02o Daily wages labour 20

Spareso Consumable Spareso Routine repairs & maintenance

Insurance charges

11.3 TARIFF STRUCTURE

Tariff under the Gujarat Solar policy 2009 has been divided for two sub periods.INR15/kWh for the first 12 years starting from the date of commercial operation of the


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SgurrEnergy India

10/60XX/001/PUN/O/R/001

project and INR 5per kWh fThis takes into account thefactor, interest on loan capoperation and maintenance

11.4 REVIEW OF FINANCIAL

SgurrEnergy has technicallSunBorne Energy.

Financial review of the projproject cost and the expecteare the generic assumptions

Financial structure: E Debt repayment peri Interest rate on debt: IDC 11% (for gesta

11.4.1 FINANCING STRUCTUR

Capital cost required for theof the finances required forworked out as INR 1461.component of the financing i

11.4.2 ANNUAL ENERGY PR

The nominal annual energyalready described in the pre

Figure

11.4.3 POWER SALE

Solar PV project revenue iKarmaria 15MW solar PVpurchase agreement execrealization through estimat

24.

12

24.

00

23.

23.

23.

4

2

3.52

2

3.

411

1 2 3 4 5 6 7


Revision B2

om the 13th onward where the PPA will be sigbenchmark capital cost, return of equity, ca

ital, depreciation factor, and interest on worosts.

ODEL

y reviewed the financial model prepared a

ect is primarily based on debt equity contri d revenue from the projects for the specified

made for the project.

quity 30% and Debt 70%d: 11 years11.00%tion period of six months)

E

15MW project is estimated at INR 2087.2 millithe project from the assumption made (debt:0 million (debt) and INR 626.20 million (eexpected to be raised from banks and financi

DUCTION

predictions for 25 years and the methodologyeding sections.

16: Nominal Individual year Energy Prediction

dependent upon the power production andproject is secured with ensured returns thrted however, it is necessary to estimate t

ed energy yield calculated. According to t

2

3.

24

2

3.

1

23.

02

22.

4

22.

32

22

.1

22

.04

22

.41

22

.3

22.

2

22.

15

22.

045

21.

35

21.25

21.1

8 9 10 11 121314151617181920212

Nominal Individual e

iled Project Report

Page 42 of 59

ed for 25 years.pacity utilizationking capital and

nd provided by

ution within theeriod. Following

on. The breakupequity, 70:30) isuity). The debtl institutes.

thus adopted is

he power price.ugh the power

he annual salee annual yield

21.

0

21.4

21.3

2

232425

ar


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Table 19: Project key indicators

Key indicators Results

Post tax project IRR 13.00%

Equity IRR 14.52%

Minimum DSCR 1.32

Maximum DSCR 2.35

Average DSCR 1.40

12 POWER PURCHASE AGREEMENT

The Power Purchase Agreement (PPA) has been executed between SunBorne EnergyGujarat One Private Limited and Gujarat Urja Vikas Nigam Limited (GUVNL) on the 31stMay 2010. Key highlights of the PPA is summarised below. Copy of original PPA has beenprovided in Appendix 5.

Validity of the power purchase agreement shall be 25 years from the date ofcommercial operation.

The project developer is required to submit a bank guarantee of INR5 million/MWpfavouring GUVNL having a validity up to three month from the date of commercialoperations.

The commercial operations date scheduled by GUVNL is 31stDecember, 2011, failingwhich project developer is liable to be pay liquidity damages of INR 10,000/day/MWfor first 60 days of delay and INR 15,000/day/MW thereafter.

Power from the solar PV plant shall be evacuated at 66kV or above, with the point ofinterconnection at the project premises. Further transmission lines and requiredelectrical infrastructure will be provided by GETCO.

Tariff rate agreed upon shall be INR15.00/kWh for first 12 years and INR5.00/kWh forthe subsequent 13years of commercial operation.

Metering shall be jointly monitored by the project developer and GETCO on first dateof every month leading in transparent administration.

Benefits of the Clean Development Mechanism (CDM) will be shared by the betweenthe power producer and GUVNL. However, the power producer will enjoy full benefitsof the Clean Development Mechanism (CDM) in the first year, after which he will sharewill reduce by 10% every year till both parties enjoy equal benefits (50:50).

13 PROJECT IMPLEMENTATIONIt is to be noted that the commercial operations date scheduled by GUVNL is 31stDecember, 2011, failing which project developer is liable to be pay liquidity damages of INR10,000/day/MW for first 60 days of delay and INR 15,000/day/MW thereafter. Project

implementation is enclosed in Appendix 7.

14 CONCLUSION AND RECOMMENDATIONS

From the analysis completed and presented in this report, the development of Karmaria15MW PV power plant is technically feasible.

Following are the recommendations by SgurrEnergy:

Site location: Site falls in close vicinity of seashore. Although all necessarymeasures may be taken for balance of plant design, confirmation from module


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manufacturer for no effect due to salt mist and excess relative humidity may berequired.

Solar Resource: For onsite measurement of resource, a monitoring station hasbeen installed on site since November 2010. The uncertainty in the energyprediction may be reduced by using a minimum of one year recorded data.

Ohmic losses: DC and AC cable size selected should be within the lossescalculated in the energy prediction, to allow a more accurate prediction of the energyprediction.

Soiling losses:SgurrEnergy advises that the O&M strategy should be designed totake into account the risk of soiling of the modules.

Supply of PV modules: Due to the large number of modules required for this PVplant, it is recommended that the lead time for delivery of the modules is confirmedwith the manufacturer and suppliers as more lead time may cause delay in projectimplementation.

Due to huge quantity of modules required for this PV plant, lead time may increase,therefore different PV module of same or higher efficiency may be considered thusimproving the energy generation.

Supply of Inverters: Initial 5MW PV plant uses SMA 800kW inverter. Delivery forthe further 10MW may vary depending on lead time; however SunBorne may opt fordifferent model and make having similar specification and warranty terms.

Effect of shading: The Karmaria PV plant suffers from significant shading lossduring the months of winter (October to March) when the tilt angle is 38. Further toreduce inter row shading, a pitch of 4.5m has been considered for designs, howevershading due to control rooms may contribute to increased shading loss in lateevening hours. This should be addressed in detail designs by optimizing the overallplant layout or increasing the land area.

Temperature effect on modules: The crystalline silicon modules that have beenselected have a power temperature coefficient of -0.45%/C. The Energy prediction

simulations use simulated temperature data. The client is advised to confirm if thesetemperature data are representative of the conditions found at site. If the averagetemperatures are found to be significantly higher, SgurrEnergy recommendssimulations should be repeated to assess the effect on the energy prediction.

Temperature effect on inverter: If the ambient temperature at site exceeds 40Cfor a significant proportion of the year, inverter losses may be higher than thosemodeled which could lead to a reduced annual energy prediction and an adverseeffect on project economics. The client is advised to confirm if the temperature datathat has been used is representative of the conditions found at site.


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APPENDIX 1: DETAILED DESCRIPTION OF LOSSES IN NOMINAL ENERGYPREDICTION CALCULATION

14.1 A1.1SHADING LOSS

Three types of shading losses have been considered in the PV energy yield model:

1) Horizon shading.

2) Shading between rows of modules.

3) Near shading due to trees and buildings.

Based on satellite imagery of the location, SgurrEnergy considers there is negligible horizonshading at the Karmaria solar PV site. The sun path diagram for the site is shown in Figure19.

(a) Winter Tilt 38 () Tilt 8

Figure 19: Horizon Shading at Karmaria PV plant

Near shading at site is caused by inter-row shading. A three dimensional model of the plantlayout has been entered into the PV modelling software as shown in Figure 20. Bysimulating the celestial motion of the sun in half hourly time steps throughout the year, themodel calculates the annual loss due to shading.

Figure 20: Model of plot at Karmaria PV plant Layout as used in the PVsyst Model


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14.2 A1.2INCIDENT ANGLE LOSS

The incidence angle loss accounts for losses in radiation penetrating the front glass of thePV modules due to angles of incidence other than perpendicular. The incident angle losshas been calculated within PV modelling software using the ASHRAE model as shownFigure 21. The loss derives from the ratio of direct and diffuse radiation and the anglebetween the sun and tilted module plane.

Figure 21: Incident Angle Modifier Curve Used By SgurrEnergy

14.3 A1.3LOW IRRADIANCE LOSS

The conversion efficiency of a PV module reduces at low light intensities. This causes a lossin the output of a module compared with the standard conditions the modules are tested at(1000W/m2). This low irradiance loss depends on the characteristics of the module and theintensity of the incident radiation. Figure 22 illustrates the reduction in efficiency due to lowirradiance. The low irradiance loss is calculated within the simulations.

Figure 22: Ex

DPR for PV plant

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