17 Samss 012
17 Samss 012
17 Samss 012
17-SAMSS-012
Photovoltaic Power Supply for Cathodic Protection
13 December 2011
Scope............................................................. 2
References..................................................... 2
Manufacturer Requirements. 3
General............................................... 4
Design Requirements.................................... 7
Site Conditions............................................... 7
Electrical Components................................... 8
Mechanical Components.............................. 16
10
Labeling Requirements................................ 19
11
12
Spare Parts.................................................. 23
13
Page 1 of 33
Scope
This Specification defines the minimum requirements for a photovoltaic (PV) power
supply for cathodic protection loads.
Any conflicts between this specification and other applicable Saudi Aramco
Materials System Specifications (SAMSSs), Engineering Standards (SAESs),
Standard Drawings (SASDs), or industry standards or codes shall be resolved in
writing by the Company or Buyer Representative through the Manager,
Consulting Services Department of Saudi Aramco, Dhahran.
2.2
Direct all requests to deviate from this specification in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Consulting Services Department, Saudi
Aramco, Dhahran.
References
Material or equipment supplied to this specification shall comply with the latest edition
of the references listed below, unless otherwise noted in the purchase order.
3.1
Inspection Requirements
ASTM A123
ASTM B209
NEMA 250
Manufacturer Requirements
4.1
4.1.2
Page 3 of 33
4.1.3
4.2
a)
b)
c)
d)
Data Sheets for the Batteries, Modules, and Array Control Center (Charge
Regulator)
General
5.1
Abbreviations
ACC
AOC
Page 4 of 33
5.2
ASC
ASME
ASTM
AWS
IEC
IEEE
NEC
NEMA
OCC
PV
Photovoltaic
RSA
SAES
SAMSS
SASD
SSPC
STC
b)
c)
d)
Page 5 of 33
Required Documentation
5.3.1
5.3.2
Page 6 of 33
Design Requirements
Each Modular PV power supply shall provide a continuous output of 90 watts at a
nominal 6 Volts and 15 Amperes (360 Ampere-Hours per Day) through an Array
Control Center (ACC). The Modular PV power supplies shall be constructed such that
the output from the ACC can be connected to additional ACCs in parallel/series
combinations via an Output Control Center (OCC) to achieve a higher voltage or
current output rating to a maximum of 24 volts, 45 amperes. The cathodic protection
load shall be connected to the power supply at the OCC. The OCC shall be constructed
with a variable resistor to control load current.
Exceptions:
1.
2.
In cases where one Modular PV power supply will provide sufficient power, an OCC is not
required if the cathodic protection load is connected to the ACC through a resistor to
control load current. In such cases, the resistor shall be mounted in a separate
enclosure.
All components of the Modular PV power supply with the exception of the batteries
shall be designed for an operational life of 20 years with minimal maintenance in a
remote, unattended, desert environment as described in Section 7. The storage batteries
shall be selected for a minimum operational life of 10 years in the same environment.
7
Site Conditions
7.1
General
Location:
Latitude:
Longitude:
17 to 32 North
15 to 55 East
Relative Humidity:
Minimum
Maximum
0%
95% (condensing)
Ambient Temperature:
Minimum
Maximum
0C (32F)
50C (122F)
Altitude:
Maximum
5000 FT
Wind:
Maximum
Gust Factor
Page 7 of 33
7.2
Onshore Environment
The normal air-borne dust concentration is 1 mg/cubic meter with 95% of all
dust particles less than 20 micrometers, and 50% less than 1.5 micrometers in
size. During sand storm conditions, dust concentration may reach 500 mg/cubic
meter and winds may gust to 146 Km/h. The dust may contain sodium, calcium,
magnesium, silicon and aluminum components. Other substances which may be
present are H2S (1 to 5 ppm), CO (50 to 100 ppm), NO(x) (1 to 5 ppm), SO2 (1 to
5 ppm), and hydrocarbons (10 to 50 ppm).
7.3
Electrical Components
Electrical components shall be rated by the manufacturer to operate in the
environmental conditions detailed in Section 7 and shall comply with NEC, Article 690.
8.1
PV Modules
8.1.1
Dimensions
Individual PV modules shall be electrically and mechanically
interchangeable between arrays of the same manufacturer and field
replacement shall be easily accomplished without specialized tools or
materials.
8.1.2
Encapsulation
The photovoltaic cells shall be mechanically and environmentally
protected. The encapsulation scheme shall provide complete moisture
and corrosion protection consistent with the environmental and life
requirements of this Specification.
8.1.3
Page 8 of 33
Contact Integrity
Each electrical connection to the active cell area shall be soldered in at
least two locations.
8.1.5
Solder
Solder employed in cell connections shall be a nominal solder alloy of
60% tin, 40% lead and shall cover all of the contact area. The solder
flux residue shall be non-corrosive to the connection alloys.
8.1.6
8.1.7
Module Frame
The module frame shall be constructed of Types 5052, 6061 or
equivalent aluminum per ASTM B209 with compatible hardware
designed to withstand the environmental conditions of Section 7.
The frame shall readily and easily accept the hardware required to attach
the module to the PV panel support structure.
8.1.8
Junction Box
Each module shall incorporate an electrical connection junction box
containing positive (+) and negative (-) module interconnection wiring
terminals mounted to the back of the module. The junction box shall be
weatherproof and shall meet the requirements of NEMA 3R.
8.2
PV Array
The array shall be wired to supply a nominal output of 6 Volts and 15 Amperes.
The array peak power shall be rated to supply a minimum of 700 watts under
Page 9 of 33
The array photovoltaic modules shall be tested to meet Section 11 and provide a
minimum of 10% conversion efficiency from incident sunlight at STC.
The modules shall be warranted to maintain at least 80% of minimum rated
power for twenty years. The effect of temperature on module power shall be a
maximum of - 0.4% for each C above the standard 25C.
8.3
8.3.1
Charge Regulator
A charge regulator shall be provided as part of the Array Control Center
to provide efficient battery charging and to prevent overcharging of the
batteries. The charge regulator shall use electronic control circuitry to
activate and deactivate sealed mercury switches.
The charge regulator shall be constructed with two sealed mercury
switches, each rated for a minimum of 50 amps DC. The switches shall
be connected in parallel such that each switch independently services
50% of the array load.
Page 10 of 33
8.3.2
8.3.3
Current Shunts
Shunts shall be Holloway type SW (or equivalent) with the ratings
shown in Figures 1 and 4.
8.4
General
The Output Control Center shall serve as a junction box for
interconnecting multiple arrays, and shall provide total system output
metering, and system load disconnect when more than one array is
required to meet the cathodic protection power requirements. A typical
schematic drawing for the OCC is shown in Appendix 2, Figure 4.
8.4.2
OCC Capacity
The OCC shall be built with a 24 Volt, 45 Amp capacity and shall
facilitate the connection of up to 12 arrays through their respective
ACCs.
Page 11 of 33
8.4.3
8.4.4
8.4.5
8.5
The meters shall have a 115 mm (4.5 in) X 100 mm (4 in) rectangular case to fit
into a 70 mm (2.75 in) round mounting hole. Four (4) mounting bolts located on
100 mm (4 in) X 89 mm (3.5 in) centers shall secure the meter to a panel of up
to 6 mm ( in) thickness.
Analog meter scales material shall be aluminum and shall be marked and labeled
in even increments of volts or amps. Each scale shall be clearly marked as 'DC
Volts' or 'DC Amperes'. The meter full-scale values shall be as illustrated in
Appendix 2, Figures 2 and 4.
8.6
8.7
8.7.2
Page 13 of 33
8.8
8.9
General
All wires shall be flexible stranded copper conductor with 600 volts
insulation, and shall be compatible with the specified environment.
Wires shall not be tapped or spliced between terminal points. Wiring
shall be neatly bundled and secured with loose fit plastic ties.
All interconnection wiring between the primary components of the PV
power supply shall be installed in flexible metallic conduits.
Conductors shall be sized for the appropriate amperage in accordance
with NEC. Minimum wire sizes shall be as follows:
8.9.2
a)
b)
c)
ACC & OCC meters and control (Internal): 0.75 mm (#18 AWG)
d)
e)
f)
Page 14 of 33
8.9.3
8.10
8.11
Each resistor shall have a minimum of seven (7) continuously welded fixed
position taps including the end terminals. Spot welded taps shall not be
acceptable.
Tap terminals shall have bolted connections with brass or phosphor bronze
hardware.
Resistors shall be stamped or engraved with the resistance and watt value for
identification.
Storage Batteries
8.11.1
8.11.2
8.11.3
8.11.4
Page 15 of 33
8.11.5
8.11.6
8.11.7
8.11.8
8.11.9
Mechanical Components
9.1
The PV array support structure shall have a fixed tilt angle of 45 for the
photovoltaic modules. It shall be designed for mounting on concrete
footings with anchor bolts.
9.1.2
9.1.3
Page 16 of 33
9.1.4
Mounting
9.1.4.1
General
The structure shall have mounting provisions for the Array
Control Center (ACC), Output Control Center (OCC), and all
associated wiring cable trays and conduits. The design shall
include space and comfortable access allowance for the control
centers and the storage battery enclosure.
9.1.4.2
9.2
Page 17 of 33
secured to the top exterior of the enclosure lid. These instructions shall also
carry any special notices by the battery manufacturer including the following:
Maintenance Instructions
1.
= _______
volts/cell
2.
= _______
volts/cell
3.
= _______
A-H/cell
Safety Instructions
9.3
1.
2.
3.
4.
5.
Close and latch cover tightly to avoid entry of sand and dust.
General
These enclosures shall be completely dust and water tight and shall be
built and rated to NEMA 4X (NEMA 250) specifications. Material
thickness shall meet the requirements of NEMA ICS 6.
The enclosure door shall have a minimum of two quick-release latches.
Metallic hinges, latches and all other metal hardware shall be Type
304/316 stainless steel.
Enclosure shall be sized to provide a minimum of 150 mm (6 in) of
working and cable bending space below the field wiring terminals.
9.3.2
Page 18 of 33
9.3.3
9.4
General
These enclosures shall be constructed with ventilated openings designed
to minimize entrance of wind blown dust and rain, and shall be built to
meet the requirements of NEMA 3R specifications.
Enclosure material shall be aluminum alloy type 5052 or equivalent.
Minimum thickness shall be based on the size of the enclosure per
NEMA ICS 6. Enclosure shall be sized to provide at least 100 mm (4 in)
of working and wire bending space all around the periphery of the
resistor.
9.4.2
9.5
10
Labeling Requirements
10.1
Page 19 of 33
depicting the factory wiring for all electrical components shall be mounted on
the inside of the ACC and OCC enclosure doors.
10.2
10.3
10.4
Manufacture's name
b)
c)
Voltage
d)
Capacity rating
e)
f)
Date of manufacture
Nameplates
An equipment identification nameplate shall be attached to the outside of the
following components by Type 304 or 316 stainless steel screws or rivets.
a)
b)
c)
Battery Enclosures
e)
f)
g)
Manufacturer
h)
Model Number
i)
Serial Number
j)
Date Manufactured
k)
l)
Page 20 of 33
11
Inspection
Inspection shall be carried out in accordance with Form 175-173100 attached to
the Purchase Order. Failure of any component to meet the requirements of this
Specification shall be justification for the Buyer's Inspector to request further
tests on similar components of that Purchase Order.
11.2
Assembly
The Manufacturer prior to Buyer's acceptance shall assemble a
complete Modular Photovoltaic power system. The purpose of this is
to demonstrate mechanical fit and size compliance of all components.
11.2.2
11.2.2.2
Short Circuit
This test shall be conducted on the ACC after it has been
preconditioned by 11.2.2.1.
Starting at room temperature the system output terminals
shall be fully short circuited with all protective devices
Page 21 of 33
Open Circuit
This test shall be conducted on the ACC after it has been
preconditioned by 11.2.2.1. The duration of test shall be
48 hours under continuous maximum DC input power.
With the system batteries in fully charged condition
disconnect the system load. At the end of test, check and
record the case temperature of all solid-state devices.
An enclosure surface temperature higher than 60C shall be
deemed unacceptable. Surface temperature of heat sinks,
diodes, and resistors higher than 110C shall be deemed
unacceptable.
11.2.3
11.2.4
11.2.5
Battery Tests
Batteries shall be tested in accordance with IEC 60896-1 or
IEC 60896-2 as applicable.
Page 22 of 33
All power for this test shall be supplied by the system's fully charged
battery bank. The load current shall be adjusted to 15 amperes from
the batteries with the simulated DC input power or photovoltaic array
disconnected. The test shall continue for 96 hours or until the battery
terminal voltage drops to below 1.85 volts per cell. Performance less
than 96 hours shall be deemed unacceptable.
11.3
12
Spare Parts
The Manufacturer shall submit within 30 days of confirmation of the order a list of
priced spare parts recommended to be on hand during system start-up and the first year
of operation.
In addition, the following spare parts shall be provided with each Modular Photovoltaic
Power Supply:
a)
b)
5% spares for all nuts, bolts, washers and other fittings required for assembly in
Saudi Arabia.
All spare parts shall be properly labeled, secured, and shipped inside the appropriate
enclosures.
13
Page 23 of 33
Batteries shall be shipped in charged and dry condition. Individual batteries shall be
wrapped and sealed against moisture. Individual cell boxes shall be printed with
handling and storage instructions, including a warning against lifting the cells by
terminal posts.
13 December 2011
Revision Summary
Revised the "Next Planned Update." Reaffirmed the contents of the document, and
reissued with minor changes to be in line with the new CSD RVL process and new industry
standards.
Page 24 of 33
Battery Type:
Equalize Voltage:
______________ volts/cell
______________ volts/cell
10
11
12
13
14
15
______________________
__________________
Time
Amperes
Time
Amperes
Time
Amperes
1 Hour
________
8 Hours
________
24 Hours
________
96 Hours
________
120 Hours
________
500 Hours
________
16
17
18
Approved By:___________________
Dwg. No.
___________________
Date: _________________________
Page 25 of 33
Appendix 2
Page 26 of 33
Appendix 2 Continued
-100
100
BATTERY CURRENT
(+)
LOAD CURRENT
(+)
(-)
50
15
MODULE VOLTAGE
(+)
(-)
(-)
61mm
24' (TYP.)
Heat Sink
Shottky Diodes
(5 Places)
61mm
24' (TYP.)
WARNING
ALWAYS SWITCH
OFF ALL PV
PANELS BEFORE
DISCONNECTING
BATTERIES
PV PANEL (+)
LOAD
CIRCUIT
BREAKER
(30A)
TYP.
PV PANEL (-)
+
BATTERY
OUTPUT
150mm
(6')
2
3
PV PANEL
CIRCUIT BREAKERS
(50 A)
Page 27 of 33
Appendix 2 - continued
Page 28 of 33
Appendix 2 continued
Page 29 of 33
Appendix 2 continued
Page 30 of 33
Appendix 2 continued
Page 31 of 33
Subject Index
Section
1
2
3
4
4.1
4.2
5
5.1
5.2
5.3
5.4
6
7
7.1
7.2
7.3
8
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.1.6
8.1.7
8.1.8
8.2
8.3
8.3.1
8.3.2
8.3.3
8.4
8.4.1
8.4.2
8.4.3
8.4.4
Subject
Scope
References
Conflicts and Deviations
Manufacturer and Vendor Requirements
Manufacturer and Equipment Qualification Requirements
Information Required With Quotation
Documentation
Abbreviations
Terms and Definitions
Installation, Operating and Maintenance Instructions
Component Data Sheets
General Design Requirements
Site Conditions
General
Onshore Environment
Offshore and Nearshore Environment
Electrical Components
PV Modules
Dimensions
Encapsulation
Cell and Intercell Connections
Contact Integrity
Solder
Front Module Cover
Module Frame
Junction Box
PV Array
Array Control Center
Charge Regulator
Array Isolation Diode
Current Shunts
Output Control Center
General
OCC Capacity
Single Modular PV Power Supplies
Multiple Modular PV Power Supplies
Page 32 of 33
Section
8.4.5
8.5
8.6
8.7
8.7.1
8.7.2
8.8
8.9
8.9.1
8.9.2
8.9.3
8.10
8.11
9
9.1
9.2
9.3
9.3.1
9.3.2
9.3.3
9.4
9.4.1
9.4.2
9.5
10
11
11.1
11.2
11.2.1
11.2.2
11.2.3
11.2.4
11.2.5
11.3
12
13
Subject
Array Interconnection Terminal Board
ACC and OCC Meters
ACC and OCC Circuit Breakers
ACC and OCC Terminal Boards
ACC Field Connection Terminal Board
OCC Field Connection Terminal Board
ACC and OCC Instrument Panels
Wires and Cables
General
Wire and Cable Terminals
Wire and Cable Identification and Labeling
Output Control Resistors
Storage Batteries
Mechanical Components
PV Array Support Structure
Storage Battery Enclosure
ACC and OCC Enclosures
General
Array Control Center (ACC) Mounting
Output Control Center (OCC) Mounting
Output Control Resistor Enclosure
General
Output Control Resistor Enclosure Mounting
Fittings & Conduit Hubs
Labeling Requirements
Inspection and Testing
Inspection
Design Qualification Tests
Assembly
Array Control Center (ACC)
Module Environmental Tests
Module Electrical Performance Test
Battery Tests
Routine Production Performance Tests
Spare Parts
Export Packing and Shipping
Page 33 of 33