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OST Energy Template Wuxi Suntech PV Modules - Technical Review Desktop Review and Factory Audit Wuxi Suntech Power Co., Ltd. October 2014 00583 - v2.0 Final Wuxi Suntech PV Modules - Technical Review Issue and Revision Record Revision Date Originator Checker Approver Narrative 1.0 08/07/2014 JF/GS/RR CM/MG OS Draft 1.1 25/07/2014 JF/GS CM OS Draft – updated following comments 2.0 17/10/2014 JF/GS AK BR Final Disclaimer This document has been prepared for the titled project or named part thereof and should not be relied upon or used for any other project without an independent check being carried out as to its suitability and prior written authority of OST Energy being obtained. OST Energy accepts no responsibility or liability for the consequence of this document being used for a purpose other than the purposes for which it was commissioned. Any person using or relying on the document for such other purpose agrees, and will by such use or reliance be taken to confirm his agreement to indemnify OST Energy for all loss or damage resulting therefrom. OST Energy accepts no responsibility or liability for this document to any party other than the person by whom it was commissioned. To the extent that this report is based on information supplied by other parties, OST Energy accepts no liability for any loss or damage suffered by the client, whether contractual or tortious, stemming from any conclusions based on data supplied by parties other than OST Energy and used by OST Energy in preparing this report. Awards and Recognitions ACQ Magazine Finance Monthly Magazine UK Technical Advisor of the Year UK Renewables Advisory Firm of the Year 2013 & 2012 2010 October 2014 │ 00583 - v2.0 Final Wuxi Suntech PV Modules - Technical Review Contents Glossary .............................................................................................................................................1 Executive Summary ...........................................................................................................................2 Overview of the company ..................................................................................................................2 Technical review of PV modules .......................................................................................................3 Independent module testing ..............................................................................................................3 Review of production machinery and key components.....................................................................4 Factory visit findings ..........................................................................................................................4 Acceptance in the marketplace .........................................................................................................6 Operational performance ...................................................................................................................6 R&D ...................................................................................................................................................6 Warranties .........................................................................................................................................6 Product Liability Insurance ................................................................................................................7 Environmental, Health and Safety Review ........................................................................................8 1 Introduction.............................................................................................................................. 10 2 Company Overview ................................................................................................................. 11 2.1 Shunfeng Photovoltaic International ............................................................................. 11 2.2 Wuxi Suntech Power Co., Ltd ....................................................................................... 11 2.2.1 Manufacturing capabilities ................................................................................ 12 2.3 Quality management system ......................................................................................... 13 3 Technical Review of Suntech PV Modules ............................................................................. 15 3.1 Module technical characteristics ................................................................................... 15 3.2 Low irradiance performance .......................................................................................... 15 3.3 Module efficiency ........................................................................................................... 16 3.3.1 Manufacturer comparison ................................................................................. 17 3.3.2 OST comments ................................................................................................. 21 3.4 Fill Factor ....................................................................................................................... 21 3.4.1 Manufacturer comparison ................................................................................. 21 3.4.2 OST Comments ................................................................................................ 25 3.5 Conclusions on manufacturers comparison .................................................................. 25 3.6 Certifications .................................................................................................................. 25 3.7 Returns .......................................................................................................................... 26 4 Module Testing ........................................................................................................................ 29 4.1 The set of validation tests ............................................................................................. 29 4.1.1 Visual inspection ............................................................................................... 30 4.1.2 Maximum Power measurement ........................................................................ 30 4.1.3 Electroluminescence imaging ........................................................................... 31 4.1.4 Insulation test .................................................................................................... 31 October 2014 │ 00583 - v2.0 Final Wuxi Suntech PV Modules - Technical Review 4.1.5 Performance at NOCT ...................................................................................... 31 4.1.6 Performance at low and intermediate irradiance .............................................. 32 4.1.7 Thermal imaging & ΔT ...................................................................................... 33 4.1.8 Hot spot endurance test .................................................................................... 33 4.1.9 Potential Induced Degradation test ................................................................... 33 4.1.10 Conclusions ....................................................................................................... 34 5 Review of Production Machines and Key Components ......................................................... 35 5.1 Suppliers of production machines ................................................................................. 35 5.2 Suppliers of materials and key components ................................................................. 44 6 Factory Visit Findings .............................................................................................................. 60 6.1 Receipt of material from supplier .................................................................................. 60 6.1.1 Polycrystalline cells characteristics ................................................................... 70 6.2 Components storage ..................................................................................................... 70 6.3 Module manufacturing process ..................................................................................... 72 6.3.1 Quality inspection during production ................................................................. 73 6.3.2 Traceability ........................................................................................................ 73 6.3.3 Material preparation .......................................................................................... 74 6.3.4 Back sheet and EVA preparation ...................................................................... 78 6.3.5 Cell tabbing/soldering and stringing .................................................................. 78 6.3.6 Soldering, EVA and back sheet lay-up ............................................................. 83 6.3.7 Lamination ......................................................................................................... 89 6.3.8 Framing and junction box assembly ................................................................. 92 6.3.9 Module cleaning and testing ............................................................................. 94 6.3.10 Final inspection ................................................................................................. 97 6.3.11 Packaging.........................................................................................................
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