Sourcing Domestic Inverter– Issues and Challenges - india ...

Solar PV – Value ChainSolar Semiconductor in thevalue chainPV SystemsMG SiliconPoly SiliconSiliconWafersPV CellsPV ModulesThin Film

Company OverviewA Vertically Integrated System Integrator providing end to end SI servicesOur Product & ServicesOverviewFamily ofmono andmulticrystallinemodulesIncorporationFinancials• Global Company founded in 2006• Subsidiaries in India & Dubai• Revenue growth from $15M in FY2008 to $95M inFY2009.Solar cellsSystemIntegration& DesignBlue ChipCustomers &SuppliersManufacturing• Strong customer base in the key markets of USA, Europe and India• Strategic tie-ups with top tier suppliers• Sizable Manufacturing– 200 MW Manufacturing Capacity in Fab City SEZ– 200MW North America /Canada Manufacturing by 2011PowerSystemsTeam• Experienced Silicon Valley Team, with strong background in high quality, hitechmass manufacturing of Semiconductors and Systems• Over 900 full-time employees as of April30, 2010Company Proprietary and Confidential

SSI High Quality processLong term Power SustainabilityThermal Cycling, Wet Leakage and other tests ensure qualityElectro Luminescence (EL) Imaging to detect Cell micro cracks prior toshipmentGuaranteed high output and qualitySample as well as in line detectionNormalVisible ImageEL Process: GoodQualityEL Process: Bad Quality

Key Milestones for Solar Semiconductor2007 – 1 st 3MW Order 2008 – Backlog over 500MW 2009 – Growth in SI business &capacity expansion‣ Incorporation ofSSPL‣ Pilot test run of Module Line‣Contract signed with Ibersolar‣ First major purchase order with SunPower‣ Commencement ofcommercial productionat Fab City‣ Possession of Fab City LandApr 06 Jan 07 July 07 Sept 07 Dec 07 Jan 08 Feb 08 Mar 08 Apr 08 Jun 08 Feb 09Jun 09‣ Obtained EOU license forKompally Unit‣ First sales contract: Fotosolar‣ Commencement of commercialproduction‣ Announced IBC Solar as astrategic partner; contract forover 100MW over next threeyears‣ UL Certification‣Customer contract with prestigious UScompany‣ISO 9001:2000 certification‣ Expansion of module manufacturing facility inHyderabad‣ Signed AS Solar contract for 224MW over 7 years‣ Signed DS Wafer Supply Contract

Solar Semi Product Quality FocusLeanmanufacturingDateCertificationAutomatedlinesNov 2007Jan 2008CE MarkISO 9001:2000certificationSPCFeb 2008Feb 2008IEC 61215certificationIEC 61730certificationSixSigmaMarch 2008April 2008CSA listingVDEcertificationQualityCirclesJune 2009UL certificationRecognized by TÜV Rheinland, a quality certifying body“Solar Semiconductor has demonstrated the emphasis and focus on the quality of their Solar Photovoltaic modules, and unequivocallygives Solar Semiconductor a leadership status in the Photovoltaic manufacturing market…they have consistency in their productionprocess and their product quality is exceptionally high”- Enrico Ruhle (MD), TÜV Rheinland, June 2008Company Proprietary and Confidential

Solar Semi Manufacturing at FabCity160µ, 2 & 3BB Tabbing and Stringing capabilityQuality process at every step200,000 sq.ft. facility Flash testing

Scalable Projects with Solar Semi TechnologyGround Mount with Tracker Commercial Roof Top Hotel Roof TopCar Port Small Residential System Residential RoofTop System

Cost Structure of Solar PV Installation. BOS cost, including inverter is significant portion of thetotal cost.

Cost Structure• Cost of Poly- Wafer – Cell- Module• Cost of Inverter.• Costly DC connections.• Inverter life issue.• Maintenance Issue

Solar PV – Long Life• Increase operating life• Inverters today have mean time betweenfailure (MTBF) of less than 10 years• Computed MTBF above 100 years has beenachieved in recent modular solar inverters.• Solar PV panels easily meet 25yrs liferequirement• Certification• Must match panel capability– Eliminate electrolytic capacitors– Avoid delicate power devices

Classifications of Solar PV System

Off-Grid DC Couple System- Indian

Off –Grid AC Couple System- e.g. SMA

Off-Grid : Pump System• No batteries/grid as buffer!•Match power consumption with power generation by controlling speed of the pump.•Make power generation as close as possible to maximum power

On Grid

Classification based on InstallationsMulti String Inverter

Classification based on Installations(Cont.d)Central Inverter

Classification Based On TopologySolar Inverter With Transformer

Classification Based On TopologySolar Inverter Without Transformer

Block Diagram of PCUControl BoardSolar PanelInputInputProtectionBoost (w/MPPT),BuckConverterHalf-BridgeInverterTransformerClassicalRectifierH-BridgeInverterChargeControllerBatteryOutputProtectionOutput

Parallel operation of PCU UnitsChallenges :PCU• Parallel operation needs synchronism of PCUs• Should have communication between PCUs• Controlling should be done based on input from each PCUs• Control should be there based on inputs from each Battery bank unitsof PCUs• Load Management control is needed• Master-Slave mechanism should be available• Control should take care of optimal operation of PCUs• Control should take care of safe operation of PCUs• Failure of one or more of PCUs should not affect Parallel Operation ofothersIntelligent Control Required

PCU (Cont.d)

Desire Features of Solar Inverter1. FlexibilityInverters required to install indoor as well as outdoor.2. ReliabilityLive span should be more than 25 years3. DurabilityWarranty for period of 5 years and AMC for a period of 20years4. ControlInverters required to be compatible with a broad palette ofthe most diverse components .5. SupportDesign/Simulation support

ComparisonComparison INDIAN INVERTERS FORGIEN INVERTERSReliability2 Years Warranty5 Year Warranty with AMC.It can be extended to 10YearsFlexibility Indoor Indoor and OutdoorDurability 20 Years Expected 20 Years has been provedControl Wireless is not available Wireless is availableStandardized & SimulationDesign & SupportCustom madesupportEfficiency less than 94% Greater than 97%Battery Voltage 24,48,96,120,240 V 24 V and 48 V are fixedSize Large size compact sizeWeight Heavy weight light weightCost Less compared to Forgien moreCertification IEC,TUV IEC,TUV,UL

Limitations1. Indian manufacturer mainly manufactures PCU .2. PCU combines Inverter and battery chargingunit.3. Indian PCU unit are custom made notstandardized to feed customer requirement3. Engineering support is minimal.

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