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Quality Inspection for Solar Modules - Raw Material, Manufacturing & Lab Tests (15.04.18)

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The presentation is a detailed study on the following:
a) Impact of solar module component on reliability
b) Raw Material - Quality Assurance
c) Manufacturing Process - Quality Assurance
d) Lab Inspection
e) On site module inspection

Published in: Business
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Quality Inspection for Solar Modules - Raw Material, Manufacturing & Lab Tests (15.04.18)

  1. 1. GENSOL CONSULTANTS PVT. LTD www.gensol.in PV Module Reliability & Quality Assurance
  2. 2. Significance of PV Modules Quality Gensol Group The lack of Quality Standards in the industry has a negative effect on the quality of modules being installed in the country today. Different manufactures follows different methodology for quality process. It is very important to know the quality standardization process of solar PV modules for Developer, Investor, EPC & O&M Contractor in solar industry as failure of modules with lead to huge loss.
  3. 3. Solar PV Module Performance Curve Gensol Group The performance of solar PV module in various phases follows the bathtub shaped curve. Fraunhofers Photovoltaic Durability Initiative Reducing Investment Risks, 2013 Defects Observed in PV Solar modules, Mike Rycroft(EE Publishers), 2016 IEA PVPS 2014
  4. 4. Impact of Solar Module Components on Reliability Gensol Group Ethyl Vinyl Acetate (EVA) sheets or solar EVA encapsulant are one of the most important components of the solar module and are responsible for its long-term reliability and performance Source -Encapsulants: Cost vs. Reliability, Brij Foot care
  5. 5. Impact of Solar PV Module Failures in Energy Gen. & Cost Gensol Group Solar PV Modules PV Investment Technical Rsik Management, Solar Bankability, 2017
  6. 6. PV Modules Quality Assurance Plan Gensol Group Implementing a Quality Assurance Plan (QAP) will efficiently diminish the technology risk associated with solar investment. Robust quality system needs to be in place for performing vigorous material level evaluation, production process and post manufacturing module level reliability evaluation. Reliability Comes From Quality Assurance Quality Assurance Testing Pre/During /Post Process Visual Inspection Proper Measurem ent Service Terms Warranty & Guarantee
  7. 7. PV Modules Quality Assurance Plan Gensol Group Raw Material Inspection In Process Inspection Final Inspection Assurance Inspection Site Inspection
  8. 8. Step I -Raw Material – Quality Assurance Gensol Group A) Glass Characteristics Class Type of Check Acceptance Norms/ Tolerance Length Major Measurement Tolerance : ± 1 mm Width Major Measurement Tolerance : ± 1 mm Thickness Major Measurement 3.2 mm ± 2 mm Transmitivity Major Indirect Measurement Normal ≥ 91.5% and Coating Impact Resistant Major Testing (Impact Tester) Not broken Appearance Major Visual 1. Scratch L ≤ 50 mm, W ≤ 0.5mm allowed one, slight scratch do not limit 2. Air bubble: width≤ 0.5mm length ≤ 50mm, n≤ 4/square meter 0.5mm ≤ width ≤ 1mm, length ≤ 30mm, n ≤ 1/square meter 3. Glass should be clarity and clean. Cleaning of the glass surface done using the rag with alcohol to wipe, Type of Check Evaluation Technique Measurement Steel ruler, angle ruler, stopwatch Electronic scale Testing Thermometer, moderator Hygrometer pull-force meter, Safety testing machine, Power tester, Illuminance meters Visual visual inspection Note –The inspection processes represented here for solar PV quality assurance & its reliability are taken from various module manufacturer’s QAP and other sources
  9. 9. Step I -Raw Material – Quality Assurance Gensol Group B) EVA Characteristics Class Type of Check Acceptance Norms/ Tolerance Thickness Major Measurement ≥ 0.03mm Dimensions Major Measurement Tolerance: 0-5mm Gel content Major Testing 75% - 95% or 8 mm Peel strength between Glass with EVA Critical Testing ≥ 60 N/cm Peel strength between EVA with back sheet Critical Testing ≥ 40 N/cm Shrinking Major Testing TD < 2%, MD < 4% Volume resistivity Major Testing ≥ 6× 10e14 Ω-cm Appearance Minor Visual No dust and other foreign material; no breakage; no stain
  10. 10. Step I -Raw Material – Quality Assurance Gensol Group C) Back sheets Characteristics Class Type of Check Acceptance Norms/ Tolerance Thickness Major Measurement 0.18-0.235 mm Length Major Measurement Tolerance: ± 0.5mm Width Major Measurement Tolerance: ± 0.5mm Back busbar width Major Measurement Accoding to drawing of cell Front busbar width Major Measurement AJ-BSF Adhensive Major Testing ≥ 10 N/cm EL Major Testing No microcrack, pollution Power Critical Measurement Average power (0- +3% × nominal power) Appearance Major Visual No visible cells crack, cells broken, any extended V shape notch are not allowed
  11. 11. Step I -Raw Material – Quality Assurance Gensol Group D) Solar Cells Characteristics Class Type of Check Acceptance Norms/ Tolerance Thickness Major Measurement 0.18-0.235 mm Length Major Measurement Tolerance: ± 0.5mm Width Major Measurement Tolerance: ± 0.5mm Back busbar width Major Measurement Accoding to drawing of cell Front busbar width Major Measurement AJ-BSF Adhensive Major Testing ≥ 10 N/cm EL Major Testing No micro-crack, pollution free Power Critical Measurement Average power (0- +3% × nominal power) Appearance Major Visual No visible cells crack, cells broken, any extended V shape notch are not allowed
  12. 12. Step I -Raw Material – Quality Assurance Gensol Group E) Ribbon Characteristics Class Type of Check Acceptance Norms/ Tolerance Thickness Major Measurement Cell connector- Tolerance: ± 0.01mm String connector- Tolerance: ± 0.01mm Width Major Measurement Cell connector- Tolerance: ± 0.05mm String connector- Tolerance: ± 0.05mm Soldering strength Critical Testing ≥ 1.5 N/mm Coating thickness Major Visual (check the report provided by supplied) 0.025mm ± 0.005mm (single side) (check supplier outgoing report) Appearance Major Visual Flatness, no stain, no deformation, no crystal, no coating-missing Thickness Major Measurement Cell connector- Tolerance: ± 0.01mm String connector- Tolerance: ± 0.01mm Width Major Measurement Cell connector- Tolerance: ± 0.05mm String connector- Tolerance: ± 0.05mm Soldering strength Critical Testing ≥ 1.5 N/mm Coating thickness Major Visual (check the report provided by supplied) 0.025mm ± 0.005mm (single side) (check supplier outgoing report) Appearance Major Visual Flatness, no stain, no deformation, no crystal, no coating-missing
  13. 13. Step I -Raw Material – Quality Assurance Gensol Group F) Anodized Al Frames Characteristics Class Type of Check Acceptance Norms/ Tolerance Width Major Measurement Tolerance: ± 0.5mm Length Major Measurement Tolerance: ± 0.5mm Mounting hole pitch Critical Measurement Tolerance: ± 0.5mm Drain hole distance Major Measurement 60 mm ± 0.5mm Angle Major Measurement 45˚± 0.25˚ Hardness Major Measurement ≥ 8 hw Coating thickness Major Measurement ≥ 15um Appearance Major Visual same color, no water stain, oil stain, contamination, scratch, coating film no broken
  14. 14. Step I -Raw Material – Quality Assurance Gensol Group G) Junction Box Characteristics Class Type of Check Acceptance Norms/ Tolerance Cable length Major Measurement Actual length ± 13mm Dimensions Major Measurement According drawings Electrical performance Major Measurement Contact resistance ≤ 10 mohms Appearance Major Visual 1. Diode polarity, quantity is right, terminal should be complete 2. No damage H) Sealant Characteristics Class Type of Check Acceptance Norms/ Tolerance Manufactured date Major Visual Within 12 months after manufacturing Expiry date Major Visual 12 months Batch No. Major Visual Within 12 months after manufacturing Appearance Major Visual No bubble, smooth, thick liquid, no damage package
  15. 15. Step I -Raw Material – Quality Assurance Gensol Group I) Flux Characteristics Class Type of Check Acceptance Norms/ Tolerance Manufactured date Major Visual Within 6 months after manufacturing Expiry date Major Visual 6 months Batch No. Major Visual Within 6 months after manufacturing Appearance Major Visual Transparent, Colourless J) Label Characteristics Class Type of Check Acceptance Norms/ Tolerance Label parameters Major Visual Module type, Pmpp, Voc, Isc, Vmpp, Impp, Series fuse rating, Tolerance of Pmpp, Weight, Dimension STC, Measuring uncertainty of power Dimensions Major Measurement Tolerance: 5-1 mm Appearance Major Visual No flaw, mildew, dirty, delamination, hole obvious defect by naked eye not allowed
  16. 16. Step I -Raw Material – Quality Assurance Gensol Group G) Palet Characteristics Class Type of Check Acceptance Norms/ Tolerance Dimensions Major Measurement Tolerance: 5-1 mm Appearance Major Visual No flaw, mildew, dirty, delamination, hole obvious defect by naked eye not allowed H) Package Characteristics Class Type of Check Acceptance Norms/ Tolerance Dimensions Major Measurement Tolerance: 5-0 mm Appearance Major Visual No broken, right painting Printing Major Visual
  17. 17. Step II - Manufacturing Process –Quality Assurance Gensol Group Solar Cells Solar Scribbling Soldering EVA & back sheet cutting Laying Lamination Framing EL Check IV Test Cleaning Packaging
  18. 18. Step II - Manufacturing Process –Quality Assurance Gensol Group A) Sorting of Cells Characteristics Class Type of Check Acceptance Norms/ Tolerance Appearance Major Visual/Manually Colour conformity or jumping colour in one module, No north, No V-type defect, No crack, No broken B) EVA & Back Sheet Cutting Characteristics Class Type of Check Acceptance Norms/ Tolerance EVA supplier Major Visual According to the BOM of production plan Supplier and Type are right EVA expiry date Major Visual 6 months Uneven cutting Major Visual Not allowed Length of the EVA & Backsheet Major Measurement EVA: +2MM Backsheet: ± 1mm
  19. 19. Step II - Manufacturing Process –Quality Assurance Gensol Group C) Cell Assembling Characteristics Class Type of Check Acceptance Norms/ Tolerance Check materials Major Visual According to the BOM of production plan supplier and type are rightCells supplier Major Visual Flux supplier Major Visual Expiry date of flux Major Visual 6 months D) Soldering Characteristics Class Type of Check Acceptance Norms/ Tolerance Ribbon adhesion with busbar and Tin covering area Major Measurement Ribbon Adhesion with busbar ≥ 1.5Nmm Tin covering area ≥ 85% Manual line: Iron temperature Major Measurement 0.2mm (Ribbon thickness) 320˚ - 350˚ 0.23mm (Ribbon thickness) 330˚ - 360˚ 0.25mm (Ribbon thickness) 340˚ - 370˚ Automatic soldering temperature Major Visual(check the setting temperature with the standard temperature) Temperature 180˚ - 210˚ Ribbon adhesion with busbar and Tin covering area Major Measurement Ribbon Adhesion with busbar ≥ 1.5Nmm Tin covering area ≥ 85% Time Control Major Measurement 3-5 sec
  20. 20. Step II - Manufacturing Process –Quality Assurance Gensol Group E) Ribbon Characteristics Class Type of Check Acceptance Norms/ Tolerance Check interconnector (connect the cells) materials as BOM Major Visual According to the BOM of production plan Supplier and size is right Check the cross connector (connect the termination) Major Visual According to the BOM of production plan Supplier and size is right Appearance Major Visual Flatness, no stain, no deformation, no crystal, no coating-missing F) Lay -Up Characteristics Class Type of Check Acceptance Norms/ Tolerance String misaligned Major Measurement ± 0.3mm Foreign materials Major Visual Not allowed EL Test Major Testing According to the EL inspection standard
  21. 21. Step II - Manufacturing Process –Quality Assurance Gensol Group G) Lamination Characteristics Class Type of Check Acceptance Norms/ Tolerance Bubbles Major Visual S ≤ 2mm (on the cell), ≤ 1pcs S ≤ 3mm (out of the cell), ≤ 2pcs String merged Major Visual Not allowed Delamination Major Visual Not allowed Foreign materials Major Visual As per plant standard Temperature Major Testing Tolerance ± 3 degrees according to EVA property Vacuum Major Testing <-99.5kpa Gel content Major Testing 75% - 95% Peel strength test Major Testing Back plate with EVA ≥ 60 N/cm Glass with EVA ≥ 40 N/cm H) Framing & Crimping Characteristics Class Type of Check Acceptance Norms/ Tolerance Comer Gap Major Visual ≤ 0.5mm Vertical Gap Major Visual ≤ 0.5mm Diagonal Difference Major Visual Diagonal ≤ 1m, Diagonal difference ≤ 2mm Diagonal > 1m, Diagonal difference ≤ 3mm Pressure Major Visual The presence of the framing machine is 0.6-0.7Mpa Comer Crimping Major Visual Polish & smooth
  22. 22. Step II - Manufacturing Process –Quality Assurance Gensol Group I) JB Fixing & Potting Characteristics Class Type of Check Acceptance Norms/ Tolerance Check junction box, fixing and potting materials Major Visual Supplier and type are right Check for JB soldering temperature Major Visual 380˚ - 400˚ J) Cleaning & Labelling Characteristics Class Type of Check Acceptance Norms/ Tolerance Appearance Major Visual According to the Manufacturers Inspection Standard for modules Label fixing Major Visual
  23. 23. Step III- Final Product In Lab Testing Gensol Group Source- TUV Rhineland,
  24. 24. Step III- Final Product - In Lab Testing Gensol Group A) Thermal Cycling Characteristics Class Type of Check Acceptance Norms/ Tolerance Solder bond or ribbon failure, usually associated with thermal fatigue Major Testing This is an extension of IEC 61215 (200 cycles). Thermal cycling is known to identify this failure; field and modelling studies imply that longer testing may be beneficial. -40° C to 85° C. B) Dynamic Mechanical Load Test Characteristics Class Type of Check Acceptance Norms/ Tolerance Cracked cells that cause hot spots and power loss Major Testing IEC 62782. Studies have shown that the combination of DML and thermal cycling can uncover this failure. mechanical stress -1,000 cycles at ±1,000 Pa) followed by thermal stress (50 cycles of thermal cycling) Source - PV Module Reliability, DNV GL, 2017
  25. 25. Step III- Final Product In Lab Testing Gensol Group D) Damp Heat Test Characteristics Class Type of Check Acceptance Norms/ Tolerance Damp Heat Test Major Testing In the IEC 61215, modules are held at a constant temperature of 85° C and a relative humidity of 85% for 1,000 hours (~42 days) E) PID Test Characteristics Class Type of Check Acceptance Norms/ Tolerance PID Test Major Testing Power loss for modules operating at large (positive or negative) bias voltage Test method: IEC 62804 Source - Photovoltaic Module Qualification Plus Testing, 2013 C) Humidity Freeze test Characteristics Class Type of Check Acceptance Norms/ Tolerance Humidity Freeze Test Major Testing In the standard IEC 61215 test modules are exposed to temperatures of 85° C and a relative humidity of 85% for a minimum of 20 hours. The temperature is then rapidly dropped to -40° C for a minimum of 30 minutes (maximum 4 hours), freezing any moisture within the module & for 10 cycles.
  26. 26. Step III- Final Product In Lab Testing Gensol Group F) Appearance/Visual Inspection Characteristics Class Type of Check Acceptance Norms/ Tolerance • Colour of cell, • Snail trails, • Bubble, • Foreign material, • Serial number, • Back sheet, • Glass, • Frame • Junction box Major Visual a) No broken, cracked, or tom external surfaces including superstrates, substrates, frames and junction boxes. b) No bent or misaligned external surfaces, including superstrates, substrates, frames and junction boxes to the extent that the installation and/or operation of the module would be impaired; c) No voids in, or visible corrosion of any of the thin film layers of the active circuity of the module, extending over more than 10% of any cell; d) No bubbles or delamination forming a continuous path between any part of the electrical circuit and the edge of the module; e) No loss of mechanical integrity, to the extent that the installation and/or operation of the module would be impaired; f) Module markings(label) is no longer attached or the information is unreadable.
  27. 27. Step III- Final Product In Lab Testing Gensol Group G) Dimensions Characteristics Class Type of Check Acceptance Norms/ Tolerance Length, width, diagonal difference & label fixing Major Measurement Length, width ± 1mm Diagonal ≤ 1m, Diagonal difference ≤ 2mm Diagonal > 1m, Diagonal difference ≤ 3mm H) Insulation Resistance Characteristics Class Type of Check Acceptance Norms/ Tolerance Insulation resistance Major Testing Module area > 0.1 square meter, ≥ 40Mohm.mm2 Module area < o.1 square meter, ≥ 400 Mohm I) Hi Pot Characteristics Class Type of Check Acceptance Norms/ Tolerance Hi-pot test Major Testing ≤ 50 µA
  28. 28. Step III- Final Product - In Lab Testing Gensol Group J) Grounding Continuity Characteristics Class Type of Check Acceptance Norms/ Tolerance Grounding continuity test Major Testing ≤ 100 mΩ K) Flash Test & IV Data Measurement Characteristics Class Type of Check Acceptance Norms/ Tolerance Electrical data measurement of vmp, imp, pmax, voc, isc, shunt resistance, series resistance, etc. Major Testing As the Technical specification; 1) Calibration on Board power than 0.1% of nominal value 2) Test power on board than 0.3% of nominal value L) Electroluminescence Testing Characteristics Class Type of Check Acceptance Norms/ Tolerance Brightness, Black finger, cross crack, Shadow, Black Area, or invalid cell, irregular crack concentration, material pollution, wrong cell printing Major Testing EL defect of any of the thin film layers of the active circuitry of the module extending over more than 10% of any cell. Total power loss of the module less than 5%. Testing I-V curve is not abnormal
  29. 29. Step III- Final Product - In Lab Testing Gensol Group M) Wet Leakage Test Characteristics Class Type of Check Acceptance Norms/ Tolerance Wet leakage test Major Testing ≤ 50 µA N) Impulse Voltage Test Characteristics Class Type of Check Acceptance Norms/ Tolerance Impulse voltage test Major Testing IEC 61730-2:2004 O) Packaging & Marking Characteristics Class Type of Check Acceptance Norms/ Tolerance Impulse voltage test Major Visual Road and sea worthy packaging as every sales market condition
  30. 30. Step IV – Assurance Inspection Gensol Group Assurance Inspection includes two principles: "Fit for purpose" (the product should be suitable for the intended purpose); "right first time" (mistakes should be eliminated). For Assurance Inspection, same sets of tests are being performed as performed during manufacturing process. The final testing process prior to deployment and is performed by a company tester who ultimately signs off on the product Safety test (Safety testing machine) Test condition Withstand voltage test: voltage 3600V, the upper limit of current 50µA,rising voltage 8S, test 1S Property After a single test, Fail light or the instrument appear bazzar alarm means unqualified
  31. 31. Step V – On Site Module Inspection Gensol Group Visual Inspection. Electroluminescence Test (prior and after installation on structure) Maximum Power determination at STC (module and arrays). PV String - Voc and Isc Measurement. IR Thermography Inspection of modules (ground and drone inspections) and electrical connection, Verification of Diodes Operation. Voltage Drop Measurement . Polarity Verification Tests. Insulation Resistance Measurement Grounding Resistance Measurements Audit of Monitoring System & Weather Stations
  32. 32. Step V – On Site Module Inspection Gensol Group Aerial inspections (from drone or airplane) of PV power plants are being conducted nowadays for defective or underperforming modules and strings which are able to detect module-level defects which cause temperature differences in the module such as diode faults, cell hot- spots, junction box heating and major differences in module efficiency. Source: Heliolytics, “Summary of DC Losses Observed using Aerial Infra-Red Inspection Across >1.6 GW”, Rob Andrews and Kristine Sinclair, 2017
  33. 33. Assurance Compliances or Testing Specification Gensol Group Compliances Comply with IEC 61215 (Edition 2005) Crystalline silicon terrestrial photovoltaic (PV) modules - Design qualification-Performance Standards IEC 61646 Thin-film terrestrial photovoltaic (PV) modules - Design qualification -Performance Standards IEC 61730 Module safety Qualification – Safety Standards UL 1703 Fire classification rating ISO 9001:2008 Module manufacturing unit Quality compliances ISO 14001 Environmental Management System Certification OHSAS 18001 Occupational health and Safety IEC 60891 PV - Procedures for temperature and irradiance corrections to measured I-V characteristics IEC 61701 Salt mist corrosion testing IEC 62716 Ammonium corrosion testing IEC 60364 Protection Against Electric Shock for low-voltage electrical installations in PV modules IEC61646 or IEC61625- Wet Leakage Test to test the electrical isolation of the housing ASTM E1171 - 15 Test Methods for Photovoltaic Modules in Cyclic Temperature and Humidity Environments IEC 60904 Measurement of current-voltage characteristics of bifacial photovoltaic devices IEC 60721 PV module’s performance capability under prolonged exposure to standard climates IEC60068-2-2 Test to evaluate the ability of the module for use/storage under high temperature IEC 61853 Validation of Models using Outdoor Test Methods IEC TS 62782 test method for performing a cyclic (dynamic) mechanical load test IEC TS 62804-1:2015 Test to evaluate the durability of crystalline (PV) modules to the effects of short-term high-voltage stress including potential-induced degradation (PID)
  34. 34. About Gensol Solar Advisory Services Solar EPC Services Solar O&M Services 11,707MW 91 MW 2200 MW Gensol Group Gensol provides concept to commissioning solar advisory, execution and operations services for Solar Projects in India and abroad. 150 Advisors Anmol Singh Evangelist +91 7698833311 anmoljaggi@gensol.in Imran Naqvi Head of Strategic Advisory & Business Development +91 9327016962 imrannaqvi@gensol.in Gurpreet Singh Head of Engineering & Operations +91 9725544301 gurpreetsingh@gensol.in Puneet Singh Jaggi Director +91 9998025820 puneetjaggi@gensol.in Pranay Mundra President +91 9850673664 pranaymundra@gensol.in Shivya Singhal Head of Supply Chain & Group CFO +91 9376703846 shivyasinghal@gensol.in 230+ Projects 70 Engineers 170+ Projects 210 Engineers 45 Projects
  35. 35. Gensol is one of the leading consultants and system integrators for Solar Power Plants. We boast of a portfolio of over 6000 MW of Solar Photovoltaic Plants. Gensol is also a channel partner to Ministry of New & Renewable Energy and installs kW scale Solar Rooftop systems on a turnkey basis with more than 42 MW of cumulative installations across the country. The information contained herein is of a general nature and is not intended to address the circumstances of any particular individual or entity. Although we endeavor to provide accurate and timely information, there can be no guarantee that such information is accurate as of the date it is received or that it will continue to be accurate in the future. No one should act on such information without appropriate professional advice after a thorough examination of the particular situation. Email: solar@gensol.in | Web: www.gensol.in | Phone: +91 79 40068235 | Twitter: gensol_tweets Gensol Engineering Pvt Ltd | Gensol Consultants Pvt Ltd | Solarig Gensol Utilities Pvt Ltd Corporate Office A2, 12th Floor Palladium, Opp. to Vodafone House , Corporate Road, Prahladnagar, Ahmedabad, Gujarat. India - 380015

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