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Optimization of Utility-Scale PV Plant Design for Three-Phase String Inverters

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Optimization of Utility-Scale PV Plant Design for Three-Phase String Inverters Optimization of utility-scale PV plant design for three-phase string inverters Kalle Trofast School of Electrical Engineering Thesis submitted for examination for the degree of Master of Science in Technology. Espoo 23.04.2020 Supervisor Prof. Matti Lehtonen Advisor D.Sc. (Tech.) Matti Jussila Copyright ⃝c 2020 Kalle Trofast Aalto University, P.O. BOX 11000, 00076 AALTO www.aalto.fi Abstract of the master’s thesis Author Kalle Trofast Title Optimization of utility-scale PV plant design for three-phase string inverters Degree programme Automation and Electrical Engineering Major Electrical Power and Energy Engineering Code of major ELEC3024 Supervisor Prof. Matti Lehtonen Advisor D.Sc. (Tech.) Matti Jussila Date 23.04.2020 Number of pages 92 Language English Abstract The share of grid-connected PV systems has increased in the global electricity production due to the moving towards utilization of renewable energy to decelerate the climate change. By designing the PV systems properly, it is possible to achieve savings from the implementation of the system. This thesis is commissioned by Ampner Oy and it concentrates to optimize utility- scale PV plant design for three-phase Ampner ACETM series string inverters. The thesis aims to determine the cost-effective PV system while considering technical restrictions set for grid-connected PV systems so that the energy injected to the grid still maximizes. The optimization focused on to find the more cost-effective solution from the two system architectures implemented with string inverters, distributed structure and centralized structure called as virtual central. In addition, the optimization determined the optimal powerblock size, that is the amount of inverters connected to single transformer. The thesis dealt with an imaginary PV system installation in Portugal Centro region for illustrating the analysis. The work compared the profitability of the systems first as a cost per power unit, of which after thecomparison was expanded also to investigate profitability as a cost per energy unit, due tothe habit where PV systems sell the energy, not power. PVsyst simulation tool was used for PV system designs was used to determine the energy yield of the systems. The simulation tool was used also to find the most optimal ratio for oversizing thePV array over the power of the inverter. It was found that the best system architecture is achieved by distributing the inverters over the PV field. Furthermore, the optimal powerblock size was found to be 10 or 11 inverters, 3 or 3.3 MW, depending if the cost per power unit or cost per energy unit was investigated. In the sensitivity analysis, it was noticed that the profitability of the system can be still improved with several methods by decreasing cabling of the system. Also, the optimal amount for oversizing the PV array over the inverter power was found between 1.3 and 1.4. Beyond, the oversizing losses and increased cabling losses decreased the profitability of oversizing. The tool for PV system design and optimization were implemented during the thesis for Ampner Oy in case of generating similar studies for the future projects. Keywords grid-connected photovoltaic system, PV system design, solar energy, solar inverter, virtual central, DC/AC ratio Aalto-yliopisto, PL 11000, 00076 AALTO www.aalto.fi Diplomityön tiivistelmä Tekijä Kalle Trofast Työn nimi Kolmivaiheisilla paneeliketjuvaihtosuuntaajilla toteutettujen suuritehoisten aurinkosähkövoimaloiden rakenteen optimointi Koulutusohjelma Elektroniikka ja sähkötekniikka Pääaine Sähköenergiatekniikka Pääaineen koodi ELEC3024 Työn valvoja Prof. Matti Lehtonen Työn ohjaaja D.Sc. (Tech.) Matti Jussila Päivämäärä 23.04.2020 Sivumäärä 92 Kieli Englanti Tiivistelmä Verkkoonkytkettyjen aurinkosähköjärjestelmien osuus on kasvanut merkittävälle tasolle globaalissa sähköntuotannossa uusiutuvien energiamuotojen suosimisen myö- tä ilmastonmuutoksen hidastamiseksi. Oikeanlaisella järjestelmämitoituksella on mahdollista saavuttaa suuria säästöjä aurinkosähköjärjestelmän toteutuksessa. Tämä diplomityö on tehty Ampner Oy:n toimeksiantona optimoimaan verk- koonkytkettyjen suuritehoisten aurinkovoimaloiden järjestelmämitoitusta Ampner ACETM sarjan paneeliketjuvaihtosuuntaajille. Tavoitteena oli määrittää kustannus- tehokas aurinkosähköjärjestelmä huomioiden PV järjestelmämitoitukselle asetetut rajoitteet siten, että järjestelmän verkkoon syötetty energia maksimoituu. Optimointi keskittyi selvittämään kustannustehokkaammaan ratkaisun kahdesta paneeliketjuvaihtosuuntajilla toteutetusta järjestelmäarkkitehtuurista: keskitetystä virtuaalikeskusinvertteristä ja hajautetusta rakenteesta. Sen lisäksi optimointi selvitti optimaalisimman teholohkon koon eli yhteen muuntajaan kytkettävien invertterien määrän. Havainnollisuuden vuoksi, työ käsitteli kuvitteellista aurinkosähköjärjestel- män asennusta Keski-Portugalin alueella. Työssä verrattiin järjestelmien kannatta- vuutta aluksi kustannusta tehoyksikköä kohden, minkä jälkeen tutkimusta laajennet- tiin kustannusta energiayksikköä kohden. Energiansaannin simuloimiseen käytettiin PV mitoituksissa yleisesti käytettävää PVsyst simulaatiotyökalua. Simulointityökalua käytettiin myös optimaalisen paneeliston ylimitoituksen löytämisessä. Työssä havaittiin parhaaksi järjestelmäsuunnitteluksi invertterien hajauttaminen. Lisäksi työssä löydettiin optimaaliseksi lohkokooksi 10 tai 11 invertteriä, riippuen verrataanko kustannusta teho- vai energiayksikköön. Tehossa kyseinen lohkokoko tarkoittaa noin 3 tai 3.3 MW:tä. Työn herkkyystarkastelussa löytyi useita tekijöitä, joilla järjestelmää voidaan parantaa entisestään. Paneeliston ylimitoitukselle invertte- rin tehoon nähden löytyi myös selvä raja-arvo, joka asettui välille 1.3 ja 1.4. Tämän jälkeen ylimitoituksesta aiheutuvat teholeikkaukset sekä kasvanut kaapelihäviö las- kee ylimitoituksen kannattavuutta. Laskentatyökalu PV järjestelmien suunniteluun sekä optimointiin kehitettiin työn yhteydessä Ampner Oy:lle, jotta vastaavanlaisia tutkimuksia on mahdollista toteuttaa myös tulevaisuuden projekteihin. Avainsanat verkkoonkytketty aurinkosähköjärjestelmä, aurinkosähköjärjestelmän mitoitus, aurinkosähkö, aurinkoinvertteri, virtuaalinen keskusinvertteri, aurinkosähköjärjestelmän ylimitoitus 5 Preface This master’s thesis was commissioned by Ampner Oy. I feel thankful to Mika Jantunen and Pasi Törmänen giving me the unique opportunity to make my thesis for the company. I thank for the interesting topic and possibility to affect the content of the thesis. I am also extremely grateful to my advisor Matti Jussila of his great support, general interest and very efficient feedback giving skills during the process. It is hard to imagine better person for the task. Special acknowledgments also to the whole team in Helsinki who have all shown interest in my thesis. Commendation to Professor Matti Lehtonen for supervising the thesis. Thanks for the feedback and especially for the help getting the thesis started. My dearest gratitude is reserved to my beloved family who have supported and helped me during my studies. Without the supportive ambiance in our family, I would not be in this situation where I am now. I want to give special thanks to my wife Kiira for her support and faith in me during the writing process. I also apologize if I have spoken a bit too much about the topics of the thesis in recent weeks. Last but not least, I would also like to thank our golden retriever Siru who took me for a walk and detached me from the writing process once in a while. Kamppi, 23.04.2020 Kalle J. Trofast 6 Contents Abstract3 Abstract (in Finnish)4 Preface5 Contents6 Symbols and abbreviations8 1 Introduction 11 2 Principles and markets of grid-connected photovoltaic systems 13 2.1 PV module................................ 13 2.1.1 Photovoltaic effect in solar cell.................. 13 2.1.2 PV module structure....................... 14 2.1.3 Electric performance....................... 16 2.1.4 Commercial PV module types for utility-scale systems.... 18 2.2 System main components......................... 19 2.2.1 Solar inverter........................... 20 2.2.2 DC combiner box......................... 23 2.2.3 Power cables............................ 24 2.2.4 MV Transformer......................... 25 2.2.5 Protection equipment....................... 26 2.2.6 Battery storage.......................... 27 2.3 Grid-connected PV system concept................... 29 2.3.1 Distributed solution....................... 29 2.3.2 Centralized solution........................ 30 2.4 Grid codes for renewable energy..................... 31 2.5 Photovoltaic system markets and trends................ 32 2.5.1 Installed capacity of grid-connected PV system........ 32 2.5.2 System price build-up...................... 33 2.5.3 Solar markets in Portugal.................... 34 3 Design of a photovoltaic power system 35 3.1 PV array design.............................. 35 3.1.1 PV string sizing.......................... 36 3.1.2 PV array power.......................... 37 3.2 Cable sizing................................ 39 3.2.1 PV string cable.......................... 39 3.2.2 Main DC cable.......................... 40 3.2.3 AC cable.............................. 41 3.2.4 Voltage drop and loss calculation................ 42 7 3.3 Protection................................. 45 3.4 MV transformer sizing.......................... 46 3.5 MV cable................................. 47 3.6 MV level structure............................ 47 4 Optimal powerblock size for string inverters
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