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7/28/2019 report on pv project
1/23
Final Project for Photovoltaic Cell class
A Proposal for Solar Grant
(Cost Estimation for Providing Electricity for 100 Village Houses in Tanzania)
Jonathan Kenneth Rhyne
Younes Sina
Huidong Zang
Sabina Nwamaka Ude
Mary Diane Waddle
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PROPOSAL FOR SOLAR GRANT
To produce electricity from the sun for domestic use requires a careful
selection of materials to ensure reliability, dependability and affordability. Many
factors need to be considered when choosing the right solar components to provide
uninterrupted power. These factors include: the right choice of PV panels with good
efficiency and low cost, knowledge of the sun insolation of the area in question and
the best tilt to capture this energy, amount of batteries needed for back-up during
cloudy days when the sun rays are blocked, the right inverters and controllers to
work with your system, site selection to avoid shading, cost of labor for initial
installation and subsequent maintenance, etc. Consideration of these factors entails
careful calculations and wise selection of the appropriate type and number of
components for optimum power production.
1. INTRODUCTION
1.1. Photovoltaic cells
Photovoltaic (PV) power systems convert sunlight directly into electricity. A
residential PV power system enables a homeowner to generate some or all of their
daily electrical energy demand on their own roof, exchanging daytime excess power
for future energy needs (i.e. nighttime usage). The house remains connected to the
electric utility at all times, so any power needed above what the solar system can
produce is simply drawn from the utility. PV systems can also include battery backup
or uninterruptible power supply (UPS) capability to operate selected circuits in the
residence for hours or days during a utility outage. Photovoltaic power offers a proven
and reliable source of electrical power for remote, small-scale facilities. PV systems turn
sunlight directly into electricity for use. Since there are typically no moving parts in PV
systems, they require minimal maintenance. While often more expensive than otherrenewable technologies, the modularity of PV systems and the broad availability of the solar
resource, sunlight, often make PV the most technically and economically feasible power
generation option for small installations in remote areas. The initial investment in a PV
system typically accounts for most of its lifetime acquisition, operation and maintenance
costs. The cost of a PV system rises in direct proportion to the total size of the loads.
1.2. Location
Due to energy losses when transporting electricity over distances, especially at the low
voltages typical of small PV projects, PV systems should be located within a reasonable
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distance of the point of energy use. Fortunately, PV modules can be placed anywhere the
sun shines, including the roof of a building. Care must be taken to secure the modules in
areas of high winds to prevent loss or damage. PV modules are very sensitive to shading.
The shading of 5% to 10% of the surface area of a module can lead to a drop in power
output of 30% to 50% or more.
1.3. Operation and Maintenance (O&M)
The minimal O&M requirements of a PV system make this technology well suited for isolated
locations and rural applications where assistance may be infrequently available. Preventive
maintenance, such as routine system cleaning and inspection, are always recommended.
The most common maintenance required for typical PV systems is the periodic addition of
distilled water to the batteries when flooded batteries are used. More expensive systems,
using sealed batteries, can run for extended periods (months) without user intervention.
When PV systems are used and managed by community organizations or system owners,
there is a critical ongoing need for training and/or assistance in system maintenance and
troubleshooting. Sometimes the malfunctioning of a small fuse can be the reason for a
system failure. In this case, a routine inspection by an experienced technician could reveal
what caused the original problem that burned the fuse.
1.4. Environmental Impacts
A PV system produces negligible pollutants during normal operation. The main
environmental impact associated with PV systems comes from the failure to properlydispose of batteries used in conjunction with the arrays.
1.5. Costs
The cost of a standalone PV system varies greatly depending on local market conditions and
the quality of the equipment used. While the PV modules themselves may cost about
US$7.00 per Watt, the total upfront investment cost of a PV system, including batteries,
inverter, installation, etc., typically is about US$20.00 per Watt installed. Costs per installed
Watt depend on system size, the installation site and component quality. Smaller systems
(less than 1 kW) tend to be at the higher end of the cost range. O&M costs for small-scale
PV systems are generally low, at less than 1% of initial investment costs annually. If poor
quality BOS components are used, these may fail and lead to higher costs to diagnose the
problem and replace the faulty components.
1.6. Viability
The PV option is most likely to be competitive when tens or hundreds of peak Watts are
required in remote or hard-to-reach areas. Depending on the situation, PV may also be
competitive when only a few kilowatts of energy are needed. In many rural areas, diesel or
gas generators and PV systems are the only viable alternatives. Unlike generator sets, PV
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systems are quiet and do not generate pollution. With proper design, installation and
maintenance practices, PV systems can be more reliable and longer lasting than generators.
The modularity of PV systems enables systems to be well matched to the demand. When
there are multiple small sites requiring electrification, PV is best installed in the form of
independent systems sized to match each individual load.
PV systems are more likely to fail in areas that lack the commercial and technical
infrastructures needed to ensure long-term sustainability. This infrastructure includes PV
markets that are active enough to sustain the field over time, including suppliers of
warranted PV system components, installers and maintenance technicians.
2. SYSTEM DESIGN CONSIDERATIONS
2.1. Basic Principles for Designing a Quality PV System
1. We selected a packaged system that meets the owner's needs. Customer criteriafor a system may include reduction in monthly electricity bill, environmental benefits,
desire for backup power, initial budget constraints, etc. The size and orientation of
the PV array is adjusted to provide the required electrical power and energy. The off
grid system selected for the village guarantees the people of the village electricity
during the entire year including the rainy season.
2. We are ensured the roof area or other installation site is capable of handling the
desired system size.
3. We specified sunlight and weather resistant materials for all outdoor equipment.
4. We located the array to minimize shading from foliage, vent pipes, and adjacent
structures.
5. We designed the system in compliance with all applicable building and electrical
codes.
6. We designed the system with a minimum of electrical losses due to wiring, fuses,
switches, and inverters.
7. We properly housed and managed the batteries and inverter systems.
2.2. Basic Steps for Installing a PV System
1. We ensured the roof area or other installation site is capable of handling the
desired system size.
2. We realized that roof mounting is better than a solar field; therefore we verified
that the roof is capable of handling additional weight of PV system.
3. We properly sealed any roof penetrations with roofing industry approved sealing
methods.
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4. We Installed equipment according to manufacturers' specifications, using
installation requirements and procedures from the manufacturers' specifications.
5. We properly grounded the system parts to reduce the threat of shock hazards and
induced surges.
2.3. Typical System Designs and Options
There are two general types of electrical designs for PV power systems for homes;
systems that interact with the utility power grid and have no battery backup
capability; and systems that interact and include battery backup as well. The village
has an off grid system with large battery banks so the people of the village have
electricity during nights as well as the rainy season.
2.4. Typical System Components
The village has typical system components as follows:
PV Array
A PV Array is made up of PV modules, which are environmentally sealed collections
of PV Cells- the devices that convert sunlight to electricity. Often sets of four or more
smaller modules are framed or attached together by struts in what is called a panel.
This panel is typically around 20-35 square feet in area for ease of handling on a
roof. This allows some assembly and wiring functions to be done on the ground if
called for by the installation instructions. The solar panel is consisted by series or
parallel connected solar cells. Thus, the work principle of the solar panel is same as
the principle of single solar cell which generates electricity by photovoltaic effect. The
photovoltaic effect refers to photons of light knocking electrons into a higher state of
energy to create electricity. Moreover, the materials presently used for photovoltaic
include mono-crystalline silicon, polycrystalline silicon, microcrystalline silicon,
cadmium telluride, and copper indium selenide/sulfide. i And the efficiency is around
10%-20%.
The PV array used for each home in this village is a roof mounted system.
The panels will be attached on the north side of each home flat against the roof. The
angle on the roof is 20, so this places the panels at 20 above the horizon facing the
equator. The array on each house will be a total of 78 panels split between the two
sections of the roof leaving one side with a 4x10 panel grid and the other a 4x10 grid
that is lacking two panels at the top. The panel we chose was a 180W panel from
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China with a 16% efficiency. The panels cost $283 dollars each. A detailed price
assessment will be discussed later.
Balance of system equipment (BOS)
BOS includes mounting systems and wiring systems used to integrate the solar
modules into the structural and electrical systems of the home. The wiring systems
include disconnects for the DC and AC sides of the inverter, ground-fault protection,
and overcurrent protection for the solar modules. Most systems include a combiner
board of some kind since most modules require fusing for each module source
circuit. Some inverters include this fusing and combining function within the inverter
enclosure.
DC-AC inverter
This is the device that takes the dc power from the PV array and converts it into
standard AC power used by the house appliances. It is a necessary component in
the system, because the solar panels and the batteries are DC source power, but the
load is AC mode. Basically, the inverter can be divided by two types, one is stand
along inverter and the other is grid tie inverter. The off grid inverter is used in isolated
solar power system. And the inverter has the following functions: Overload
protection, Sort circuit protection, the over-voltage protection, overheating protection.
We chose a 220V 50Hz 3kW inverter/charge controller from China. This unit has the
inverter and the charge controller built into one unit. Each unit costs $1,757. Every
house will have one active unit and another deactivated united on site for a
replacement after the 5 yr life of the active unit is exceeded. The peak load that each
house will experience throughout the day is 1.6kW which is within the limits of the
unit.
Metering
This includes meters to provide indication of system performance. Some meters can
indicate home energy usage.
Battery backup system components
Because all of the energy produced by the solar modules at any given time need to
be stored as chemical energy, thus a battery bank is installed to collect and store
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excess energy to use when needed. The batteries used in solar applications are
usually specialized, deep-cycle lead acid batteries.
The battery backup system include of the followingcomponents:
1. Batteries and battery enclosures
2. Battery charge controller
3. Separate subpanels for critical load circuits
This by far is the most expensive section of the project. The batteries themselves are
cheap, $168, however the quantity needed to sustain each house through the rainy
season is tremendous, 862 batteries per house. This totals 86,200 batteries for the
village at a cost of 14.5 million dollars! This number could be tripled if the batteriesonly last 3 yrs and the grant is to provide power for 10 yrs. Since we are only
discharging the batteries to their rated depth of discharge once a year, we are
hoping that the batteries will last longer than this.
Charge controller
A charge controller, charge regulator or battery regulator is one of the necessary
components in the solar power system. It limits the rate at which electric current is
added to or drawn from electric batteries. The most important factor of charge
controller is preventing the overcharging that may prevent against overvoltage, which
can reduce battery performance or lifespan, and may pose a safety risk. It may also
prevent completely draining ("deep discharging") a battery, or perform controlled
discharges, depending on the battery technology, to protect batterys lifetime. The
terms "charge controller" or "charge regulator" may refer to either a stand-alone
device, or to control circuitry integrated within a battery pack, battery-powered
device, or battery recharger.
This photovoltaic system is designed as an off-grid system that will withstand
extreme temperature variations. This off-grid system is in Africa where its proximity
to the equator and height influences the intensity of the sun. The more intense the
sunlight, the more watts the solar panels will produce. This effect will increase the
voltage and will potentially damage the batteries. The batteries are of major
economic concern for an off-grid system and their importance is paramount. A
charge controller is used to regulate the charging voltage to the batteries.
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Charge controllers use a three stage cycle as bulk, absorption, and float. The
graph below will illustrate the relationship between amps and voltage.
Fig1. Relationship between amps and voltage through the charging cycle
There are two multistage charge controllers used in PV systems; pulse widthcontrollers (PWM) and maximum power point tracking (MPPT). Pulse width
controllers maintain the constant voltage need, while the mppt match the battery
voltage to the output of the solar array. The controllers primary purpose in a PV
system is to handle the maximum current produced by the solar array. The
considerations in selecting a controller are as follows:
High/Low voltage disconnect
Temperature Compensation
Low voltage warning
Voltage meters/reverse current protection
These considerations must be analyzed to insure the batteries and the PV system is
protected.
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Fuse, wire and switches
The function of fuse is to protect the solar power system and the standard of
choosing fuse, wire and switches need to consider the value of current used in the
situation of maximum output. The wire chosen for this project was tin plated copper
wire that costs $0.805 per meter. We will require 5000m of wire for the complete
system in the village.
Other components
Utility switch
2.5. PV Installation
There are several ways to install a PV array at a residence. Often the most
convenient and appropriate place to put the PV array is on the roof of the building.
The PV array may be mounted above and parallel to the roof surface with a standoff
of several inches for cooling purposes. In this project we decided to install the PV
arrays on the roof of the houses to reduce the cost of wiring and also to reduce the
risk of damage from accidental human and animal interference. The batteries and
inverter/charge controller will be housed in a 25ftx25ftx8ft basement to the right of
each house shown in figures 2.5.1 and 2.5.2.
Figure 2.5.1 black square is the house, the red the basement, the blue lines are the distance between
houses, and the arrows say there are ten rows with ten columns.
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Figure 2.5.2 gray is the walking space, the blue is the battery rows and the green is the inverter
There will be five rows of batteries that are that are 7 batteries high and 25 batteries
long. The inverter will be in the lower corner depicted by the green square. This
space also gives extra space for the spare inverters and panels.
3. Estimating System Output
PV systems produce power in proportion to the intensity of sunlight striking the solar
array surface. The intensity of light on a surface varies throughout a day, as well as
day to day, so the actual output of a solar power system can vary substantial. There
are other factors that affect the output of a solar power system. These factors arestandard test condition for modules, temperature, dirt and dust, mismatch and wiring
losses, and DC to AC conversion losses.
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The first step in estimating the power required for the village was to calculate the
load each house has per day. This number was figured from the numbers below.
Lights
25W*10lamps*12h/day = 3kWh/day
Refrigerator
700kWh/yr*yr/365days = 1.91781kWh/day
Television
125W*5h/day + 15W*19h/day = 0.91kWh/day
Air Conditioner
750W*24h/day = 18kWh/day
Computer
200W*5h/day + 10W*19h/day = 1.19kWh/day
Washing Machine
0.25kWh/wk*wk/7days = 0.03572kWh/day
Total = 25.05353kWh/day/house
So each house uses ~25kWh/day. Next we found the insolation for the latitude and
longitude of the village using the NASA surface meteorology and solar energy
website. This site is very useful and gives virtually every parameter needed to
perform any calculation and provides long term averages of 22 yrs for the data. The
data we used is selected in red below in figure 3.
Figure 3 solar insolation at 18 averaged for each month
The slope of the roof is 20, so we took the data for 18 above the horizontal facing
the equator. We used the lowest insolation month to figure the number of panels.
The lowest month is June with a value of 4.55kWh/sq.m/day which is in winter. The
calculation was: 25.05353/(4.55*0.18*0.4) which gives 77 panels. The 0.18 is the
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watt rating of the panel in kilowatts and the 0.4 is for total system efficiency. The total
be seen in table 3.
Table 3 the red numbers are the individual efficiencies used and the blue number is the total
Average PV System Component Efficiencies
PV array80-85%
Inverter80-90%
Wire97-98%
Disconnects, fuses98-99%
Total grid-tied PV system efficiency60-75%
New batteries (roundtrip efficiency)65-75%
Total off-grid PV system efficiency (AC)40-56%
The number of batteries was found by taking the total amount of charge required to
sustain the house for the 3 month rainy season. It was given that each house
receives 2 days of sunshine per week at random during the 3 months. Looking at the
calendar, it is likely that there will be a total of 9 days total sunshine in both the
months of Aug. and Sep. while Oct. will likely have 8. This results in a total of 26
days, the rest of the days will be discharging from the battery. The calculations for
this can be seen in figure 3.1 below.
Figure 3.1 excel calculations used to determine the system size
The 2nd row is the insolation per month, the 3rd is the excess kWh produced, the 4th
the sunny days in that month, and the 5th the total excess kWh produced during that
month. The numbers in the 6th row are the sum of the corresponding color numbers
above, the purple is the pre-spring months and the blue the post-spring ones. The
pink numbers in the 7th row are the total kWh discharged from the batteries for that
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month and the total below them. The gray is the total kWh held in the 862 batteries
at 80% depth of discharge. It is slightly above the pink total discharged over the
spring months. The orange numbers in the last row are the kWh added back to the
batteries. The middle number is a sum of the other two which is greater than the pink
discharge total. This means that the batteries are fully recharged for the spring
months every year. It turns out that the panels needed to be increased to 78 in order
for this to happen. The batteries are fully discharged to 80% and recharged once a
year.
4. Cost calculations
4.1. Cost of components
The cost for each components and the shipping information is listed in follow. Fig.4.1
shows the cost breakdown of components.
4.1.1. Controller and inverter (integrated system)
http://shayanjian.cn.alibaba.com/Company: Shanghai Jinxian Solar Tech Co. Ltd
Tel: +86 21 5227 4750 (Mr. Jianghong Sha)
Model: HT22030J7
Output: 220V 50Hz 3000W
Price $1757
Size after packing 1m*1m*2m
Due to the peak hour power needed in a single house 1655Wh
The total controller and inverter integrated system would be
2 unit per house/ one active and one replacement with 4 spares
The total cost for controller and inverter integrated system: $1757*204=$358,428
4.1.2. Solar wires
Company: Shanghai Yingqiang Electronic Co. Ltd
http://shayanjian.cn.alibaba.com/http://shayanjian.cn.alibaba.com/http://shayanjian.cn.alibaba.com/7/28/2019 report on pv project
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http://liyoch.cn.alibaba.com/
Tel: +86 21 5947 0669 (Mr. Yongchun Li)
Model: PV1-F TIN PLATED COPPER WIRE
Brand: Yongben
Price: $0.805/m
The length of wire is calculated based on the map in the assignment, assuming the
height of house is 4m. (5000m is needed)
So the total cost for wire is 5000m*0.805/m=$4025
4.1.3. Battery
Company: Shenzhen Haonaite Power Co. Ltd
http://detail.china.alibaba.com/company/detail/yhz9394.html
Model 12V200AH
Size: 522*238*218mm
Price: $158 plus $10 for box
# Batteries per house 862
The total cost $168*862*100= $14,481,600
4.1.4. Fuse and switches
Fuse-Company: Shenzhen Weilangte Electronic Co. Ltd
http://shenzhenweilangte.manufacturer.globalsources.com.cn/si/6008828299332/Ho
mepage.htm
Model: UDA/UDA-A
Max current: 10A; Max voltage: 250V
Size: 5mm*20mm
http://liyoch.cn.alibaba.com/http://liyoch.cn.alibaba.com/http://detail.china.alibaba.com/company/detail/yhz9394.htmlhttp://shenzhenweilangte.manufacturer.globalsources.com.cn/si/6008828299332/Homepage.htmhttp://shenzhenweilangte.manufacturer.globalsources.com.cn/si/6008828299332/Homepage.htmhttp://shenzhenweilangte.manufacturer.globalsources.com.cn/si/6008828299332/Homepage.htmhttp://shenzhenweilangte.manufacturer.globalsources.com.cn/si/6008828299332/Homepage.htmhttp://shenzhenweilangte.manufacturer.globalsources.com.cn/si/6008828299332/Homepage.htmhttp://detail.china.alibaba.com/company/detail/yhz9394.htmlhttp://liyoch.cn.alibaba.com/7/28/2019 report on pv project
15/23
Price: $0.02
# fuses: 500 PCS
The total cost $0.02*500= $10
Switch-Company: Zhengtai electronic Co. Ltd.
http://www.chint.net/index.php
Model: NB1-63 220V 50Hz
Price: $3.5
# fuses: 300 PCS
The total cost $300*3.5= $1,050
4.1.5. Panels
Table4.1.5. shows some panel providers from different countries with deferent types,
models, dimension efficiency and price. The GOD Company from China is selected
as the panel provider for the village.
Panel Cost: $283x 7800=2,207,400
4.2. Transportation Cost
4.2.1 Shipping from Shanghai to Tanga
40 gp container: 12.01m*2.33*2.38m Price: $630
Company: Sinotrans Container Lines Co., LTD
Website:http://www.sinolines.com/
4.2.1.1. Panels
The size of panel after packing approx: 1.8m*0.9m*0.1m
# of panels 78*100=7800 pieces
So approx 300 panels per container
# of containers for panels: 7800/300=26
http://www.chint.net/index.phphttp://www.chint.net/index.phphttp://www.sinolines.com/http://www.sinolines.com/http://www.sinolines.com/http://www.sinolines.com/http://www.chint.net/index.php7/28/2019 report on pv project
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# cost for shipping panels = $630*26= $16,380
4.2.1.2. Controller and inverters
The size of container is 12.01m*2.33*2.38m
The size of controller and inverter is 1m*1m*2m
So each container can load 12 systems
# Containers = 204/12 =17 containers
Cost for controller and inverter is $630*17 = $10,710
4.2.1.3. Wires, Fuses and Switches
1 container is enough.
# Cost = $630
4.2.1.4. Batteries
According to the size of container and batteries
Each container can load 2400 batteries
So # container is 86200/2400= 36
Cost for shipping batteries
# 36*$630= $22680
Total cost for shipping
$16,380 + $10,710 + $630 + $22,680 + $1,060= $51,460
Fig.4.2. shows the cost breakdown for the shipping of the components.
4.2.2. Transportation cost by truck
Total cost: $516,600
1300 trips/2$ per mile/ 216 miles
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Fig.4.2.2 shows the distance from the port to the village that is the basis of shipping
by truck.
Fig.4.2.2. Distance from the port to the villageFig.4.Fig.
4.3. Site Preparation cost
4.3.1. Site Access Clearing
Labor: 10 men X 20 days X 8hrs X 5$ = $8,000
Tools: 10 saws X 20 days X 10$ = $2,000
Bulldozer: 30 days X 500$ = $15,000
4.3.2. Battery bank place
Hole creation for battery bank : 20 days X 500$ = $10,000
Basement : $500 per house X 100 homes = $50,000
4.3.3. Total site preparation costTotal cost = 60,000(basement)+15,000(bulldozer)+2000(chain saw)+8000(
labor)=$185,000
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Fig.4.3.3.1. shows the cost breakdown for site preparation.
Fig.4.3.3.2 shows a view of the region. The red line shows the road access to thevillage.
Fig.4.3.3.2. A view of the region(the red line shows the road access to the village)
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4.4 .Training cost
Training cost for labors - 9 people :$10,800
Engineer for training :$ 7,200
Labor for installing panels :$24,480
Fig.4.4. shows cost breakdown of training and installation
Fig.4.4. Cost breakdown of training and installation
0
5000
10000
15000
20000
25000
Labor training Engineers for
training
Instalation cost
10800
7200
24480
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Fig.4.1 Component cost breakdown
Fig.4.2. Cost breakdown for the shipping of the components
Controler/Inverter
2%Wiring
0%
Battery
85%
Fuse
0%
Swich
0%
Panel13%
Component Cost Breakdown
Panel
33%
controllers,Inverter
s
21%
Wire, Swich, Fuse
1%
Battery
45%
Cost Breakdown for the shipping of the
component
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Fig.4.3.3.1. Cost breakdown for the site preparation
4.5. Total cost
Table 4.5.1 and 4.5.2 show a summary of the costs.
Table4.5.1. Cost of components
Basement
59%
Battery Bank place
12%
Bulldozer
18%
Tools
2% Labor
9%
Site Preparation Cost Breakdown
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Table4.5.2. Cost for transportation, installation, training
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Country Company Type Model Dimension PowerVoltage(Vpm)
Efficiency
Price(RMB)
Lifetime(y) Max. V Max. I
USA Sharppolycryst
alND-
130UJF662*1499*46mm 133W 17.4V 13.10% 25 600 15
China Suntechpolycryst
alSTP130D-12/TEA
1482*676*35mm 130 17.4 25 1000 20
China Suntechpolycryst
alSTP135D-12/TEA
1482*676*35mm 135 17.5 25 1000 20
Solarworld
Mono-crystallin
e SW2301675*1001*34mm 230 29.6 $600 25 600 15
China Leixinpolycryst
al 689*1480 140w 36V13Y*140
W= 25 3.88A
China Jinnuo
Mono-crystallin
e KD-M1801580*808
*35 180W 36.3 1414.5Y*18
0W 25 800 5.61A
China GOD
Mono-crystallin
e GOD-1801580*808
*35 180 36 1611Y*180=
$283 25
China Leixinpolycryst
al 200w*10 2000w
China Xinan
Mono-crystallin
e XA2301580*106
0*50 230 46.4V 25 4.96
XA2401580*106
0*50 240 46.9V 25 5.11
XA2501580*106
0*50 250 47.2V 25 5.3
China Xuhuipolycryst
al XH-Sp2201640*992
*50 210 28.9814.87*210
=3124 25 7.25
220 29.61 3124 25 7.55
230 29.4 3124 25 7.82
China SULO
Mono-crystalline
sol180s-24d
1580*808*35
China Jieyupolycrystal TY-160
1581*808*40 160W 34.5 16 RMB8888 25 700V 4.46
Table4.1.5. Data about panels