ACKNOWLEDGEMENT & PROJECT OVERVIEW

The aim of this project report is to estimate and calculate the approximate design of a 1MW solar PV
power plant (utility scale) so that we can come out with an approximate design of a 100MW solar PV
power Plant.

The total number of solar panel required and the different parameters of the solar panel estimated
using the solar intensity for Zimbabwe.

Also the brief details of the materials /equipments (solar panels, inverters, protective gears,
transformer, SCADA etc) used to set up a 100MW power plant are to be highlighted in this paper.

A financial overview with possible income datasheet is also to be included in the report.
 TECHNICAL CALCULATION/ESTIMATION & SPECIFICATION

WORKSHEET FOR DETERMINING THE REQUIRED NUMBER OF SOLAR PANELS

Total capacity of the plant 1Mp

Average sun hours per day 6

Total power per day 6MWp

Total watt-hr per day 6x1000x1000 W-h/day

Maximum solar insolation at the site 8.09KW-h/m^2/day

Divide total watt-hrs/day by solar insolation 741656.3659

Multiply this figer by 1.2 (to cover system inefficiency) 741656.3659x1.2=889987.639

Divide this figure by the Wp of the chosen solar panel 3068.92 ~ 3069
to obtain the number of solar panels (here 290Wp)

SOLAR PV ARRANGEMENT AND OVERALL SYSTEM RATING

Rating of solar panel

Wattp 290Wp
DC Voltage (Vmp(V)) 36.8V
DC Current (Imp (A)) 9.25A
Open Circuit Voltage (Voc (V)) 44.9
Short Circuit Current (Isc (A)) 8.53

SETUP OF PANELS AS PER REQUIREMENTS

By calculation and the demand of the plant, the total number of PV panels to be used = 3069
From 3069, total 3072 panels are considered to generate the required energy-1MW. For better
efficiency and to utilize the inverter and other components.

CONFIGURATION DETAILS:

3072 Panels are divided into 2 groups - each group containing 1536 solar panels. In each group,
1536 panels are further divided into 64 strings (parallel connection). Each string contains 24 solar
 panels (series connection). So we will be having 100 groups of this configuration to generate a total
power of 100MW so the total number of PV modules required is 307200.

ELECTRICAL CALCULATION

Output voltage of each string 36.8x24 = 883.2 VDC

Output current of each string 9.25 ADC
Output voltage of each group 550.8 VDC
Output current of each group 9.25x64 = 592 ADC
NOTE: in each string, the solar panels are connected in series to increase the voltage.
And in each group, the 64 strings are connected in parallel to increase the current.

DC OUTPUT POWER CALCULATION

Output power of each string 883.2x9.25 = 8169.6 (8.2 KW)

Output power of each group 524.8 KW
Output power of 2 groups 1049.6 KW

The 100 MW solar power plant will be having a DC Output power of 104.96 MW as per this design.

LAND REQUIRED CALCULATION

Number of PV Modules required 3072

Dimensions 1.66m X 0.99m
Number of modules in array 24
Total width of each PV array 24 X 0.99 = 23.76m
Length of one PV module 1.66m
Number of PV modules in an array 1536
Number of arrays in a row 2
Width of the solar field 2 X 23.76m = 47.52m
Number of rows in a solar field 64
Pitch distance between two arrays 2m
Length of the solar field 64 X (2+1.66) = 234.24
Land required for PV field 47.52m X 234.24=11131.0848s.qm
Land required for PV field in acres (1 acre=4047s.q m) ~ 2.7 acres (~~1.12ha)
For 100MW with 5m pitch distance between 2 MW ~275.17 acres (~~112ha)
Total land required to construct a 100 MW (with all substations ~350 acres (~~142ha)
and a control room)

The above specifications are available with Aelo Modules. Their module spec AELO S19 mono-crystalline Si
(High efficiency) has been used as a reference. The datasheet/spec. sheet of Aero S19 mono-crystalline has
been provided in this report.
INVERTER DETAILS AND SPECIFICATION; TYPE OF THE INVERTER CONSIDERED; SOLIVIA CL 600

Recommended specification

Input (DC)

Max input power 600kWp

DC voltage range, mpp (UDC) 450 - 850 V
Maximum DC voltage (Umax (DC)) 900V
Maximum DC current (Imax (DC)) 2x628 A
Voltage ripple < 2.5%

OUTPUT (AC)

Nominal AC output power (PN (AC)) 540kW

Nominal AC current (IN (AC)) 2x534 A
Nominal output voltage (UN (AC)) 3 phase 330V
Output frequency 50/60 Hz
Harmonic distortion, current < 2.5 %
Power factor compensation (cos∅) Yes

To meet the above stated criteria, SOLIVIA CL 600 Inverter manufactured by Delta Energy Systems
(India) PVT Ltd
Total of 2 inverters of SOLIVIA CL 600 inverter type required to generate the 1MW power, so we
need 200 inverters for the 100MW Solar PV Power Plant.

TRANSFORMER DETAILS AND SPECIFICATIONS

The system inverters typically provides power output of order 480VAC. Electricity grids operate at
much higher voltages of the order of tens or hundreds of thousands of volts, so transformers are
incorporated to deliver the required output of the grid.

Recon’s Oil Cooled Distribution Transformers were used as reference. Recon covers a wide range Oil
Cooled Transformers with Off Circuit Tap Changer? On Load Tap Changer (up to 5000 KVA in 11 KV &
33 KV) conforming to the international standards of quality and safety for industries and commercial
set-ups.

100 Transformers 33 KVA - 1000 KVA

2 Transformers 132 KVA - 100 MVA

STANDARD SPECIFICATIONS

Capacity 5000 KVA

No. of Phase 3 Phase
Frequency 50 Hz
Voltage Range 11 KV / 22 KV / 33 KV
Tapping On Load Tap Changer for + −5% to 15%
Taps in steps of 1.25%
OR Off Circuit Tap Changer for +−5%
Taps steps of 2.5% each, on HT side
Insulation Class ‘A’
Vector Group Dyn 11
Duty Cycle Continuous
Winding Copper Wound
Terminals As per required

PV LIGHTINING COMBINING BOXES.

 24pcs Solar panels are connected in series and totally we can get 64 groups solar panel lines
 The 64 groups solar panel lines are connected with PV lightning protection combining box
(16 lines input and 1 line output)
 The output line from PV lightning protection combining box is connected with 600KW in grid
Inverter.
 Finally 2pcs 600KW in-grid Inverters are parallel and connected with utility grid.

PV Lightning protection combining box 18 lines input

600KW Inverter 16pcs
1 MW 32pcs
100MW 3200pcs

THE MAIN PROTECTIONS AND PROTECTIVE GEARS

DC SIDE PROTECTION

FUSES

1. For string protection

2. Fuses for array / Inverter Input protection

FUSE HOLDERS

1. For string protection

2. Panel mount fuse holder
3. In-line fuse holders
4. Array / Inverter Input protection
5. Dead front fuse covers
SURGE PROTECTION DEVICES

DC SWITCH

1. Load break disconnect switches

2. High power switches

COOLING DEVICES

1. Air and liquid cooled solutions

WIRE MANAGEMENT SOLUTIONS

1. Finger- safe power distribution blocks

2. Finger -safe comb wiring bar

GROUNDING-FAULT PROTECTION

AC SIDE PROTECTION

1. Circuit breaker
2. Bar contractor
3. Insulation monitoring device

The safety and protection of the modules and plant equipments, protective gears from Schneider
Electric have been considered for maximum benefits and used as reference in this paper.

SCADA SYSTEM FOR THE POWER PLANT

In a solar plant , data acquisition system is very important because we have to monitor the overall
system condition including Input/output condition, temperature, solar Insolation, Weather
condition, voltage/ current fluctuation, output power condition, surge effect, load dispatch etc.

SOLIVIA has to provide the monitoring facility/ SCADA for the power plant and the SOLIVIA CL 600
inverter itself has an In-built SCADA system.

So, for the monitoring and controlling of the over all power system of the plant, SOLIVIA SOLAR
SCADA system is recommended here.
 FINANCIAL ANALYSIS & FEASIBILITY

INITIAL INVERSTIMENT IN TERMS OF COMPONENTS COST & SERVICE CHARGES

UNIT PRICE TOTAL COST

ITEM COMPONENTS / SERVICES QUANTITY REMARKS
(USD) (USD)
1 Solar PV modules 290.00 307200 89,088,000.00
2 Solar inverters 125,000.00 200 25,000,000.00
3 33KV Transformers 5,000.00 100 500,000.00
4 320KV Transformers 30,000.00 2 60,000.00
5 Solar PV modules combiners 2,000.00 3200 6,400,000.00
6 Module mounding structures 800.00 6400 5,120,000.00
7 Protective devices 100,000.00 - 100,000.00
8 Wires / Cables 300,000.00 - 300,000.00
9 SCADA 8,000.00 - 8,000.00
10 Project execution & commissioning 1,000,000.00 - 1,000,000.00
11 Construction works 1,000,000.00 - 1,000,000.00
12 Grid evacuation 200,000.00 - 200,000.00
13 Other official works 500,000.00 - 500,000.00
TOTAL PROJECT COST 129,276,000.00

Total expenses over the year for plant O&M and staffing = $ 4 000 000.00 ,this expense is considered
for regular maintenance cleaning of PV array, checking the status of inverter, cable-faulty,
emergency maintenance & replacement of components and annual salaries of O&M team of the
plant.

FINANCIAL ESTIMATION

Total investment $ 140,000,000.00

Yearly plant maintenance
Electricity produced per year
ZESA tariff
Gross outcome from the plant per year
Net income from plant per year @ fixed
value
$ 4,000,000.00
216000MWh or 216000 000 units per year
6 cents/ unit
$ 12,960,000.00
$ 12,920,000.00

Payback period (linear method) 10.8 4years