Solar PV system sizing

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Agenda

1) Sizing of DC-coupled off-grid systems

2) Sizing of grid-connected systems

AGENDA
3) Inter-row shading

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Sizing of DC-coupled off-grid systems

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Off-grid system design overview

§ Design and sizing (dimensioning) are not the same thing

§ System design involves choosing the most appropriate system
configuration
§ Detailed sizing is done after this has been decided
§ A clear understanding of customer requirements is required for a successful
design

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Design philosophy

§ A good design philosophy aims at producing ‘sustainable’ systems –

systems which not only ‘work’ when first installed, but which can be
successfully operated and maintained over many years.
§ This includes asking questions such as:
§ Where will the customer get a replacement battery when it comes to the
end of its life?
§ Will the customer (e.g. a remote school or a clinic) be able to afford to
purchase a replacement battery of that type and size?
§ Is it be better to have several smaller systems with smaller batteries
(easier to replace and do not require replacement at the same time)?
§ Is it better to have a ‘centralized’ mini-grid?
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§ Is local expertise sufficient to maintain the type of system being

proposed, especially in the case of larger systems?
§ Can system performance be checked/measured (monitoring) without
dismantling part of the system?
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Pre-sized systems

§ Many companies sell pre-sized systems

§ For example, a company might sell a 100 Wp system, a 500 Wp system
and a 2,000 Wp system
§ This avoids having to design and size systems for each individual customer
§ However, such pre-designed systems are based on a pre-determined load
profile and an assumption of the solar irradiation, temperature, local
conditions, etc.

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System sizing

§ Once a design concept has been more or less decided upon, the next thing
to do is to
§ Estimate the daily energy requirement

§ Calculate the average daily solar irradiation during the worst month

§ Based on that, you can size the different system components and
accessories

§ Note: the design concept may be revised as a result of this

§ Note: there are several methods used to size systems

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Design and sizing process

§ The process generally consists of the following distinct steps (for a DC-
coupled system with inverter but without any other power source such as a
diesel generator):
§ Decide on a design concept – for example, several DC-only systems or a
single large system serving several buildings (DC-coupled. AC-coupled
or hybrid)
§ Determine required PV array size and type and number of modules
§ Determine required battery bank size (voltage and capacity) and type
and number of batteries
§ Select charge controllers and inverters
§ Select and calculate AC & DC cables sizes (voltage drop)
§ Select accessories (protective devices, fuses, breakers, etc.)
§ Make a materials list
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§ Draw up cabling/wiring plans

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Sizing methods

§ Systems can be sized using

§ Manual methods (pencil and paper)
§ Sizing forms / worksheets / excel-based sizing sheets
§ Software

§ Results obtained by one method can be used to check results obtained

by using another method

§ Manual sizing (pencil, paper, pocket calculator) involves being able to

size a system from scratch. It can only be done if one understands the
system energy flows. All designers should be able to do this, and the
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only way to learn is to practice. Manual sizing is ideal for initial sizing

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Review: daily electrical energy demand calculation

Appliance Quantity Wattage Hours Watthours Total wattage

Low energy lights 5 11 4 220 55 12VDC
LED path lights 10 1 5 50 10 12VDC
Desk lamps 2 13 4 104 26 230VAC
Laptop 1 30 8 240 30 230VAC
TV & Video 1 80 2 160 80 230VAC
Computer printer 1 20 0.5 10 20 230VAC
Ansaphone 1 5 24 120 5 230VAC
Fridge 1 80 8 640 80 230VAC
Stereo 1 50 3 150 50 230VAC
Total loads 1694 356

This is where all off-grid system design begins

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Total daily demand = 1694 Wh

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 Review: daily solar irradiation

Latitude (decimal degrees): 14.853

Longitude (decimal degrees): -15.798
Radiation database: PVGIS-SARAH2

year month H(i)_m Daily average

2020 Jan 199,22 6,43
2020 Feb 204,03 7,29
2020 Mar 236,61 7,63
2020 Apr 221,31 7,38
2020 May 219,28 7,07
2020 Jun 188,55 6,29
2020 Jul 182,84 5,90
2020 Aug 183,38 5,92
2020 Sep 182,42 6,08
2020 Oct 209,69 6,76
2020 Nov 198,04 6,60
2020 Dec 195,60 6,31

H(i)_m: Irradiation
www.renac.deon plane at angle (kWh/m2/mo)
We use the daily irradiation value at
the worst month

Source: PV GIS
PVGIS (c) European Union, 2001-2022

In this case: 5.90 PSH

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Sizing of PV array

§ To calculate the PV array size, we can use the formula:

𝑇𝑜𝑡𝑎𝑙 𝑑𝑎𝑖𝑙𝑦 𝑒𝑛𝑒𝑟𝑔𝑦 𝑑𝑒𝑚𝑎𝑛𝑑 𝑊ℎ

𝑃𝑉 𝑎𝑟𝑟𝑎𝑦 𝑠𝑖𝑧𝑒 𝑊𝑝 =
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑑𝑎𝑖𝑙𝑦 𝑃𝑆𝐻 ℎ𝑟𝑠 ∗ 𝑃𝑅

Where PR = Performance Ratio (Efficiency of the PV system)

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Sizing of battery bank (I)

§ 𝑺𝒕𝒆𝒑 𝟏: we need to calculate the initial capacity of the battery required for
the daily energy demand:

𝑇𝑜𝑡𝑎𝑙 𝑑𝑎𝑖𝑙𝑦 𝑒𝑛𝑒𝑟𝑔𝑦 𝑑𝑒𝑚𝑎𝑛𝑑 𝑊ℎ

𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝐴ℎ =
𝑆𝑦𝑠𝑡𝑒𝑚 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 (𝑉)

§ 𝑺𝒕𝒆𝒑 𝟐, we need to adjust the initial capacity of the battery taking into
consideration battery efficiency:

𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 − 𝑠𝑡𝑒𝑝 1 𝐴ℎ

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𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝐴ℎ =
𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
§ Lead acid batteries efficiencies of ~ 80 - 90% can be expected, however this decreases with
use, age, sulphation and stratification.

§ Lithium-Ion batteries have typical efficiencies of over ~ 95%

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Sizing of battery bank (III)

§ 𝑺𝒕𝒆𝒑 𝟑: we should not discharge the battery fully and need to set a certain
depth of discharge (DoD):

𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 − 𝑠𝑡𝑒𝑝 2 𝐴ℎ

𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝐴ℎ =
𝐷𝑜𝐷
§ Lead acid batteries: DoD should be around 50%, can go up to 80% (not recommended)

§ Lithium-Ion batteries: DoD 80-95%

§ Finally, we should consider the duration of the autonomy:

𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝐴ℎ = 𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 − 𝑠𝑡𝑒𝑝 3 𝐴ℎ ∗ Autonomy (days)

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§ Typical autonomy for countries with good irradiation: 3 days

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Sizing of charge controller (I)

§ First, we select the system voltage (battery bank voltage): the charge
controller should be compatible with the system voltage, in our example: 12V

§ Second, we estimate the maximum voltage of the PV array:

§ Our PV array size is: 400 Wp
§ We need 4 x 100 Wp modules
§ 100Wp module, Voc (STC): 23V, average temperature worst month: 24°
§ Parallel-connection, so Voc = 23V, charge controller should have at least 30V rating

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Sizing of charge controller (II)

§ Third, we estimate the maximum current of the PV array:

§ We need 4 x 100 Wp modules
§ 100Wp module, Isc (STC): 5.85A
§ Parallel-connection, so Isc = 4* 5.85A = 24 A, charge controller can have 40A rating

§ Finally, we estimate the maximum current output:

𝑇𝑜𝑡𝑎𝑙 𝑑𝑎𝑖𝑙𝑦 𝑝𝑜𝑤𝑒𝑟 𝑊

𝑂𝑢𝑡𝑝𝑢𝑡 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝐴 =
𝑆𝑦𝑠𝑡𝑒𝑚 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 (𝑉)
!"#
𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = $%
= 30 A
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§ We can select a charge controller with 40A rating

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Sizing of Inverter

§ First, we select the system voltage (battery bank voltage): the inverter should
be compatible with the system voltage, in our example: 12V

§ Finally, we select an inverter that can match the AC power demand:

§ In our example, this is: 291W

§ We can select an inverter with 350W size

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Sizing forms / worksheets

§ Sizing forms or worksheets can

be very useful
§ Most text books on this subject
will provide forms, as will
organisations and companies
involved in PV-based rural
electrification
§ Some forms are pretty
straightforward, others can be
very complex
§ All will have different
approaches, mainly reflecting the
experience of the person who
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designed the form

§ They will have limitations/blind
spots
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Hankins sizing worksheets / spreadsheets

Excel sizing worksheets

§ Free but designed to be used with the book ‘Stand-alone Electrical

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Systems’ by Mark Hankins
§ Suitable for PV-only up to 1,000 Wp
§ Available here: www.routledge.com/books/details/9781844077137/

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PV-diesel hybrid systems

§ For PV-diesel hybrid systems up to approx. 2,000 Wp, a sometimes useful

rule of thumb is to size the PV array so that it provides the energy for all the
loads powered via the batteries, ignoring those loads which are powered
directly by the generator
§ The use of software for sizing large hybrid systems is recommended
§ AC-coupled mini-grids
§ More complex, but not unsimilar
§ Suppliers often provide guidelines / software

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Design and sizing software

§ Software programmes can also be used to design and size off-grid PV

systems
§ They take time, skill and knowledge to learn how to use properly
§ They are not a short-cut, and if you do not have sufficient knowledge their
use can be counterproductive
§ Learn how to size systems manually and using forms/worsheets first,
before using software
§ Before purchasing software and/or learning to use free software, be sure
that it is suitable for the type of system that you are designing/sizing

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Software

§ Free / online sizing tools:

§ PVGIS – http://re.jrc.ec.europa.eu/pvgis/
§ Hankins Excel, free, but book needed -
http://www.routledge.com/books/details/9781844077137/
§ Software from solar companies (free or free to customers):
§ PV-diesel hybrid systems, DC-coupled and AC-coupled
§ Commercial systems (demo versions usually free of charge):
§ PV*Sol – http://valentin-software.com/
§ PV*Syst – http://www.pvsyst.com/
§ Solar pumping:
§ Grundfos WEBCAPS – http://www.grundfos.com
§ Other renewable energy software, for very large systems:
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§ HOMER– https://www.homerenergy.com/
§ RETScreen – http://www.retscreen.net/es/home.php

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PVGIS – system size check (1)

Enter system location and details

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System performance can be checked using PVGIS

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PVGIS – system size check (2)

Programme gives expected battery performance etc.

Percentage
of days
when battery
is 93-100%
charged
when the
sun sets.
The ideal
situation is
when this
occurs on
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over 90% of
days.

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Sizing of grid-connected systems

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Project feasibility

§ The following factors should be assessed to determine initial project

feasibility:
§ Requirements and purpose of the system
§ Will all electricity be fed into the grid in a FiT/PPA scheme?
§ Will part of the electricity be used internally in a net metering scheme?
§ Will the PV system be used as option for load shaving, etc.?
§ A precise understanding of local metering/pricing is required
§ Space available for the installation
§ Solar irradiation available at the location
§ Budget available for the project
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Designing and sizing systems

§ There is no one correct way to design and size (dimension) systems

§ Designers and installers use different methods. This reflects the
experiences of different experts working in different countries and under
different conditions.
§ Systems need to be designed for their entire working lives
§ Systems need to be designed so they can be maintained (e.g. module
cleaning is possible, spare parts are available)

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2 Sizing of grid-connected systems

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The design and sizing process (simplified)

Available space for PV array (m2)

PV array size (Wp), quantity of PV modules

Selected inverter(s) and match with PV array

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Inter-row shading

Background information: inter-row shading

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 Using software for inter-row shading

Distance
between rows
(minimum

nt
e m
m
o .co
m ar
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th sol
e
Tilt angle at .rbi
ne w
RBI Solar Shade Calculator : li w
https://www.rbisolar.com/SolarCalculatorHTML5/index.html ff- : w
O e
Se
31
Berlin (52º)

§ December 21st at 9 am

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Berlin (52º)

§ December 21st at noon:

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Berlin (52º)

§ December 21st at 3 pm

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Calculation of distances between rows of panels

§ Distance D between module rows (end-to-end) :

distance (D) width (w)

w ∙ sin(180°- β - α)
D=
sin(α)
β

inclination
with: α = 90° - 23,5°- latitude angle (β)
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What size will it be? GIZ

https://www.giz.de/en/downl
oads/Sizing_handbook_150
dpi_for_web.pdf

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Software

§ With Sunny Design software, you can plan tailor-made PV systems for your
customers. It could be a grid-connected PV system with or without a
battery-storage system, smart energy management or e-mobility, an off-grid
island or hybrid system - Sunny Design takes all technical specifications for
the various components into account and provides you with relevant data
for a cost-effective assessment of the system. That means that you can
match your PV systems to suit the circumstances on-site.
§ https://www.sma.de/en/products/apps-software/sunny-design.html

§ The mini-grid builder is a tool developed by GIZ

§ https://www.minigridbuilder.com/

§ HOMER Pro
§ https://www.homerenergy.com/products/pro/index.html
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Thank you!

Renewables Academy (RENAC)

Schönhauser Allee 10-11
D-10119 Berlin
Tel: +49 30 5 870 870 - 00
Fax: +49 30 5 870 870 - 88
[email protected]