Installation & Commissioning Report

128 KW Grid-Tied Solar Power Plant

Installed at: Masood Spinning Mill (MSM) Kabirwala

Installed By:
Premier Energy (Pvt) Ltd.
Solar Power plant Commissioned on: 24 August 2015
Signed By:

____________________
Mahmood Ahmed
Manager Technical Operations
Premier Energy (Pvt.) Ltd

____________________
Fazal Yasin
Manager Electrical
Masood Spinning Mill (MSM)

Background
Solar power in Pakistan is most suitable solution because of energy crisis, load shedding and power crisis.
Pakistan covers 796,095 square kilometers of land between latitudes 24 and 36north and longitudes 61
and 76 east. At present, it faces serious energy problems: 95 per cent of its electricity generation comes
from hydropower, which becomes less productive during the driest, hottest months of the year and cannot
keep pace with the sharp rise in energy demand. Also, about 70 per cent of the population lives in some
50,000 villages dispersed around the country. Many of these villages are far from the main transmission
lines of the national grid and, because of their relatively small populations; it is usually not economically
viable to connect these villages to the grid. Solar energy, on the other hand, has excellent potential in
areas of Pakistan that receive high levels of solar radiation throughout the year. Every day, for example,
the country receives an average of about 19 Mega Joules per square meter of solar energy. Hot, sunny
climate, long daytime hours and unstable grid power generation makes solar energy an ideal solution for
Pakistan. Kabirwala, due to its more summer hours, is ideal for solar power plant.
Before start of this project at Masood Spinning Mill (MSM) , we utilized meteorological data, using
temperatures, radiation scores and longitude and latitude readings to design the perfect solar energy
system customized according to the requirements of our clients. Air ducts roof were selected for
installation due to easy access to LT Room of Unit 2.

Project Details:
It is a 128KWp Grid tied project and consist of four grid tied ABB inverters TRIO-27.6-TL-OUTD.In
This System total 504 panels are used. 100 panels of Canadian solar and remaining 404 panels of
SunTech Solar are used. Inverter 1, 2, 3 is fed by DC input of 32.13 KWp that means 126 panels of 255W
for each inverter and remaining 4th inverter fed by DC input of 31.63KWp that means 100 panels of
250W and 26 panels of 255W. Each inverter consists of two MPPT controllers. Three strings of 21 panels
each are connected to each MPPT and in this way 6 strings are connected to each inverter. So we have a
total of 24 strings for 4 inverters. As the open circuit voltage of the panel is 37V, so the string voltage is
more than 700V in peak hours, suitable for MPPT operation in independent mode.
The DC cable used for each string to inverter is 6mm and the inverter to grid AC cable is 95mm and the
support structure consist of galvanized coated iron. For protection AC and DC disconnect switch, DC
over voltage surge arresters and AC over voltage surge arresters and string protection fuses are available
for each inverter. Also on AC side ABB 120 Ampere 4 pole breaker is used for every inverter. The
inverters are grounded using 4mm cable and Main DB panels is grounded by 35mm earth wire and
connected with main LT room earth point for earth protection. A set of 126 panels is made and is
grounded with 4mm cable.

Installed Equipment:
SR#
01
02
03
04
05
06
07
08
09
10
11
12
13

Accessory Name
Solar Panel (Poly)
Solar Panel (Poly)
Mounting Frames(Suntech)
Mounting Frames (Canadian)
Bolts for Panel fixing
Nuts for Panel fixing
Washers for Panel fixing
Bolts for Frames fixing
Nuts for Frames fixing
Washers for Frames fixing
Rawalbolts
Rawalbolts Washers
1 Core DC Cable

14

2 Core DC Cable

15
16
17
18

PVC Pipe
PVC Pipe
Earthing Wire frame to
frame
Earthing Cable

19
20

Flexible pipe
Pipe joints, Bends, T joints

21

Socket

21

Communication wire

23

Communication Connector

24

AC wire

25

AC Breaker

26

Combined DB Panel

27

Cable Duct

28

Cable ties

29

Regular tap

30

HT Tap

Specs
Suntech 255W
Canadian 250W
GI Adjustable
GI Adjustable
GI, 13mm,1
GI, 13mm
GI, 14mm
GI, 13mm,3
GI, 13mm
GI, 14mm
M8 (5/16)
GI
6mm,Pure
cupper shielded
cable
6mm,Pure
cupper shielded
cable
1 Popular Pipe
3 Popular Pipe
4mm single core
35mm From DB
to Load
1 flexible pipe
1 Popular Pak
Arab
1 Popular Pak
Arab
Networking
cable
485 to RS232
converter
95mm 4 core
shielded cable
Fast Cable
80-100 A AC
breaker ABB
Polarized
coated iron
80 x 80 mm
8 PVC Cable
Ties
PVC Regular
Tap
HT Tap for
Connections

Quantity
404
100
408
100
1112
1112
1112
1410
1410
1410
1150
1150
405m

Total
404 Panels
100 Panels
408 Frames
100 Frames
1112 bolts
1112 Nuts
1112 Washers
1410 bolts
1410 Nuts
1410 Washers
1150 Rawalbolts
1150 Washers
405m 1 Core DC
Cable

734m

734m 2 Core DC
Cable

177 lengths
13.5 lengths
540 m

135 lengths
13.5 lengths
540 m

65 m

65 m

8 bundle
100 pieces
of each item
150 pieces

8 bundle
100 pieces of
each item
150 pieces

60m

60m

65 m

65 m

Set

Set

48 Feet

Cable Duct 48
Feet
13 Packets Cable
ties
8 Bundle Regular
tap
1 HT Tap

13 Packets
8 Bundle
1

31

Copper Sleeves

32

Copper Thimbles

33

Grid Tied Inverter

35mm Copper
sleeves
35mm, For Ac
output Wire
Connections
27.6 KW Grid
Tied Inverter

Solar Panel Commissioning Data

Solar Panel Technical Data:
Model:
SCT STP255-20/Wem:
Company/Brand:
Suntech Polycrystalline
Voltage Optimum:
30.8 Volts
Short Circuit Current:
8.76A
Open Circuit Voltage:
37.6V
Operating Module Temperature -40 C to +85 C
Maximum System Voltage
1000 V DC (IEC)
Maximum Series Fuse Rating 20 A
Power Tolerance 0/+5 %
STC: irradiance 1000 W/m2
Module temperature 25 C, AM=1.5
NOCT STP255-20/Wem
Maximum Power at NOCT (Pmax)
Optimum Operating Voltage (Vmp)
Optimum Operating Current (Imp)
Open Circuit Voltage (Voc)
Short Circuit Current (Isc)

188 W
28.1 V
6.68 A
34.7 V
7.12 A

NOCT: Irradiance 800 W/m2.

Ambient temperature 20 C, AM=1.5, wind speed 1 m/s.
Temperature Characteristics:
Nominal Operating Cell Temperature (NOCT) 452C
Temperature Coefficient of Pmax
-0.42 %/C
Temperature Coefficient of Voc
-0.33 %/C
Temperature Coefficient of Isc
0.067 %/C

18 pieces
20 Pieces

18 pieces Copper
Sleeves
20 Pieces Copper
Thimbles
Two 27.6 KW
Grid Tied Inverter

Panel Installation Configuration:

Total Panels:
SunTech 255W:
Canadian 250W :
Total no of Strings:
Total no of panels per String:

504
404
100
24
21

Grid Tied Inverter:

Technical Data and Types:
Type code TRIO-27.6-TL-OUTD-S2X-400/JP

Input side:
Absolute maximum DC input voltage (Vmax,abs)
1000 V
Start-up DC input voltage (Vstart)
430 V (adj. 250...500 V)
Operating DC input voltage range (Vdcmin...Vdcmax)
0.7 x Vstart...950 V
Rated DC input voltage (Vdcr)
620 V
Rated DC input power (Pdcr)
28600 W
Number of independent MPPT
2
Maximum DC input power for each MPPT (PMPPTmax)
16000 W
DC input voltage range with parallel configuration of MPPT at Pacr
500...800 V
DC power limitation with parallel configuration of MPPT Linear derating from max to null
[800VVMPPT950V]
Maximum DC input current (Idcmax) / for each MPPT (IMPPTmax) 64.0 A / 32.0 A
Maximum input short circuit current for each MPPT
40.0 A
Number of DC inputs pairs for each MPPT
5
DC connection type Tool Free PV connector WM / MC4
Input protection:
Reverse polarity protection for inverter only, from current limited source, with max 2 string connected
Input over voltage protection for each MPPT varistor 2
Input over voltage protection for each MPPT - plug in modular
surge arrester (-S2X version) 3 (Class II)
DC switch rating for each MPPT (version with DC switch)
40 A / 1000 V
Fuse rating (versions with fuses )
15 A / 1000 V
Output side:

AC grid connection type Three Phase 3W+PE or Three phase 3W+N+PE

Rated AC power (Pacr @cos=1 )
27600 W
Maximum AC output power (Pacmax @cos=1)
27600 W
Maximum apparent power (Smax)
30000 VA
Rated AC grid voltage (Vac,r)
400 V
AC voltage range
320...480 V
Maximum AC output current (Iac,max)
45.0 A
Contributory fault current
46.0 A
Rated output frequency (fr)
50 Hz / 60 Hz
Output frequency range (fmin...fmax)
47...53 Hz / 5763 Hz
Nominal power factor and adjustable range >0.995 Adj 0.8 with max 30kVA
Harmonic Distortion of Current each <3%, total<5%
AC connection type Screw terminal block, cable gland PG36
Output protection:
Anti-islanding protection
Maximum AC overcurrent protection
Output overvoltage protection Output overvoltage protection - plug in modular surge arrester
(-S2X version) 4 (Class II)
Operating performance:
Maximum efficiency (max)
Weighted efficiency (EURO/CEC)
Feed in power threshold
Stand-by consumption
Communication:
Wired local monitoring
Remote monitoring
User interface Graphic display

Passive, Active
46.0 A
varistor 4

98.2%
98.0% / 98.0%
40 W
< 8W

PVI-USB-RS232_485 (opt.)
VSN700 Data Logger (opt.)

Environmental:
Ambient temperature range
-25...+60C /-13...140F with derating above 45C/113F
Relative humidity
0...100% condensing
Sound Power Level in accordance with ISO
3741 <53 dB(A)
Maximum operating altitude without derating
2000 m / 6560 ft
Physical:
Environmental protection rating
Cooling Natural
Dimension (H x W x D)
Weight
Mounting system Wall bracket
Safety:
Isolation level Transformerless

IP 65
1061 mm x 702 mm x 292 mm
65 kg inverter + 15 Kg wiring box

Installation
Installation of Solar Power plant with 128 KW Installed capacities was carried out in two stages.

Installation Phase 1
Before starting the work
Before starting the work our engineers compared the theoretical readings with the practical readings by
taking different short circuit test of SunTech panel (255W) at different tilt angles at Kabirwala.

They observed that the best output (8.3A) was achieved at tilt angle of 28 degree.
The panel orientation towards south was adjusted for maximum output.
A reference panel was set for the maximum output.

Panels installation were observed to be difficult because Air Ducts were 5 feet height from roof surface.,
Also it was too difficult to work during day time due to hot weather and working was then started at night
time and after that it was shifted at day time.
Panels installation
Work force for panel installation:

Two Engineers
Four Assistant Engineers
Two Technicians

Installation started:
Four assistant Engineers and two technicians started panels mounting in the supervision of two Engineers.
Panels were properly fixed with galvanized frames and then the structure was mounted on the roof using
proper bolts. All 404 panels were mounted by the same manner. 100 panel of Canadian solar was already
installed.
Making strings:
Strings were made by connecting a set of 21 panels to achieve the desired DC voltage level for the ABB
inverter. In this way a total number of 24 strings were made from all 504 panels.
Cables and cable piping:
A 6mm cable was used to connect each string with inverter, the connection was properly punched and
then insulation tape was used to ensure the safety. The cables were laid in the PVC Pipe and trenched into
the room.

Installation Phase 2
In this phase the four on-Grid inverters of ABB, AC cable 95mm, Cable for grounding, DB Panel and
other necessary accessories were transported to Kabirwala.
Grounding:
All panels were grounded in four working days using 4mm cable. A set of 126 panels were made and was
grounded with 4mm cable and connected with main DB Panel earth wire .The inverters were grounded
using 4mm cable. Similarly the DB panel was grounded using 35mm cable and connected with earth
point of LT room.

Inverters and DB installation:

The inverters were hanged on walls of the inverter room, two on each side of the room and beside of the
door DB Panel was hanged. The DB panel consist of 4 AC breakers, out of this four breakers were 80A to
100A (one for each inverter). The AC and DC cabling were done by proper PVC piping.

Checking polarity and string voltages:

The polarities of each string were then checked through multi meter and then male and female connecters
were connected to the positive and negative terminals of the strings accordingly. Meanwhile the string
voltages were checked at the same time it was observed 700 volts minimum in all 24 strings.

Solar Panel String Voltages

The polarities of each string were checked in field and then in inverter room through multi meter and then
male and female connecters were connected to the positive and negative terminals of the strings
accordingly. Following were the voltages of the strings with cable nomenclature:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

String Name

Voltage in field

Inverter 1- 1 A
Inverter 1- 1 B
Inverter 1- 1 C
Inverter 1- 2 A
Inverter 1- 2 B
Inverter 1- 2 C
Inverter 2- 1 A
Inverter 2- 1 B
Inverter 2- 1 C
Inverter 2- 2 A
Inverter 2- 2 B
Inverter 2- 2 C
Inverter 3- 1 A
Inverter 3- 1 B
Inverter 3- 1 C
Inverter 3- 2 A
Inverter 3- 2 B
Inverter 3- 2 C
Inverter 4- 1 A
Inverter 4- 1 B
Inverter 4- 1 C
Inverter 4- 2 A
Inverter 4- 2 B
Inverter 4- 2 C

726.70 V
720.44 V
723.42 V
728.91 V
740.03 V
743.28 V
718.15 V
719.17 V
727.57 V
718.56 V
734.99 V
718.32 V
738.62 V
741.79 V
723.16 V
721.81 V
732.13 V
719.32 V
695.38 V
694.22 V
695.21 V
696.44 V
695.47 V
720.09 V

Voltage in
Inverter Room
719.6 V
709.8 V
714.8 V
721.7 V
729.1 V
732.8 V
710.2 V
711 V
719.3 V
710.4 V
727 V
710.3 V
729 V
733.4 V
715.3 V
712.2 V
723.1 V
710.3 V
690.2 V
689.3 V
690.2 V
691.2 V
690.4 V
714.6 V

Connecting the PV system to the Grid

The four inverters were connected to the Grid through a 95mm AC cable.
Configuration of the inverters

The independent mode was selected for the inverter, so that each the MPPT
independently
The Italian grid standards were selected( equivalent to WAPDA Standards)
The language selected was English
The time was set according to the Pakistan standard time

will operate

Operation Start
All the four inverters were configured in the presence of ABB representative and were synced with
WAPDA. The operation was ok and all the inverters were working properly.

Commissioning Details:
Commissioning of this grid-tied solar power plant was carried out at 2:10 pm on 24 August 24, 2015.
With breaks of ten minutes duration all inverters were turned on one by one. Results were recorded which
at 2:00 pm were:
Inverter 1:

23.5 KWh

Inverter 2:

23.8 KWh

Inverter 3:

23.3 KWh

Inverter 4:

22.9 KWh

Communication and Monitoring:

Inverter communication is made possible with 485 networking protocol. For monitoring Aurora
Communicator software is used. An all inverts data displayed on desktop computer. An updating Email is
enabled for daily production monitoring. A Fault Email is also enabled so that in future if any fault may
occur then addressed that faults accordingly.

Checks & Protections:

PANEL:
Open Circuit Voltage Check:

Short Circuit Current Check:

All 504 Panels were found with 32 Volts and above (in peak
hours).
All 504 Panels produced 7 A and above (in peak hours)

All panel connections are checked and isolated and protected and proper grounding is made by earthing
wire.
INVRERTER:
Inverter output and all other parameters as per technical datasheet and check accordingly. All inverters
connection checked and all inverters a properly earthed with earthing wire.
DB Panel:
DB panel Isolation and connection checked. All cable connections are correct, isolated and protected. DB
panel is properly earth with LT Room earth wire.
Communication:
All communication setup is already checked. All inverters monitored on desktop computer and their
parameters.

Single Line Diagram of 128Kwp Solar Grid Tied PV system:

Special Thanks:
Premier Energy and its Project Team are thankful to Mill Management to support us in
energy stage of project which is no doubt looks very professional working.

Remarks:
Premier Energy recommends regular cleaning of PV Panels will be maintained.

Signed By:
____________________
Mahmood Ahmed
Manager Technical Operations
Premier Energy (Pvt.) Ltd
(Pvt) Ltd

____________________
Fazal Yasin
Manager Electrical
Masood Spinning Mill (MSM)