4.7.

Cost Analysis

4.7.1 Cost Estimation of DG Installation

Solar PV modules, inverters, batteries, and charge controllers are collectively the components of
traditional solar PV power plants.

PV modules must be selected based on a variety of criteria, such as their efficiency, price,
lifetime, and environmental impact. In order to offer the best performance and fair rates, these
variables must be taken into account during the selection process.

After that, comparing mono- and poly-crystalline modules is the first step in choosing a PV type.
As a result, polycrystalline modules have a little better efficiency than monocrystalline panels.
But polycrystalline panels are more expensive than monocrystalline ones.

A well-known and reliable type of solar cell is a monocrystalline panel of the ART245-60-1
module, which can be used in grid-tied solar power plants. As a result, the monocrystalline-type
PV module was utilized in this work. In Table 4.7 below, the basic characteristics of the selected
modules are discussed in detail.

Table 4. 7: Basic characteristics of Suniva ART245-60-3-1PV type module

The Suniva ART245-60-3-1 PV module data Values Unit

Maximum power( Pmax ) 240 W
Maximum power point voltage(V mpp) 30.65 V
Maximum power point current( I mpp) 7.82 A
Open circuit voltage(V oc ) 37.08 V
Short circuit current( I Sc ) 8.33 A
Voltage temperature coefficient(β) -0.332 %/C
Current temperature coefficient(α) 0.036 %/C
Power-derat factor(γ) -0.465 %/C
Efficiency 14.9 %
Module Temperature -40 to +90 °C
Fill Factor 77.6 %
Irradiance 1000 W/m2
Length 165.3 Cm
Width 98.2 Cm
Area 1.62 Cm2
Max system DC voltage 1000 V
Warranty 25 Years(yr.)
Price per watt Dollar($)

A. Size of PV modules required

The equation below determines how many PV modules are needed in both parallel and series
configurations.

Rated power (P rated )

N umber of modules required (N m )=
Panel maximum power (P max )

P rated 6,000,000 W
Hence, N m = = = =25,000 modules
Pmax 240 W

Again by considering the PV module, and inverter losses,

Rated power ( Prated )

Total module required ( N T )=
Panel maximum power ( Pmax )∗losses factor

6,000,000
Total module required ( N T )= =25,767.88 ≈ 25,768 modules
240∗0.98∗0.99

From the total number of modules required, the number of necessary PV modules in series ( NS PV
) and parallel (NP PV )is obtained as given in equations () and () respectively:

(¿ V ) 1000
Number of modules ∈series ( N S PV )=Dc nominal voltage DC
= =32.62 ≈ 33
Maximum power point voltage ( V mpp) 30.65

Total number of modules 25,768

Modules∈¿ ( N PPV )= = =780.8 ≈ 781 modules
Number of modules∈ series 33

As a result, to generate 6,000,000W of power, 25,768 modules with a maximum capacity of

240W each was distributed as 33 series modules and 781 parallel strings.
On the other hand, the actual output power has been computed using the actual maximum
voltage (V mpv ) and the actual maximum current ( I mpv) of the PV as determined by equations (3.8)
and (3.9), respectively.

V mpv = Total 𝑠𝑒𝑟𝑖𝑒𝑠 𝑚𝑜𝑑𝑢𝑙𝑒𝑠 ∗ 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑝𝑜𝑤𝑒𝑟 𝑝𝑜𝑖𝑛𝑡 𝑣𝑜𝑙𝑡𝑎𝑔𝑒( V mpp )

(3.8)

= 33∗30.65 = 1,011.45𝑉

I mpv = Total 𝑃𝑎𝑟𝑎𝑙𝑙𝑒𝑙 𝑠𝑡𝑟𝑖𝑛𝑔𝑠 of modules ∗ 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑝𝑜𝑤𝑒𝑟 𝑝𝑜𝑖𝑛𝑡 𝑐𝑢𝑟𝑟𝑒𝑛𝑡

(3.9)

= 781 ∗ 7.82 = 6,107.42𝐴.

As a result, the PV array's real maximum output power can be determined as equation (3.10)

Pdc = V mpv ∗ I mpv

(3.10)

Pdc = 1,011.45 V∗ 6,107.42A = 6,177,350𝑊𝑎𝑡𝑡

Radiation and temperature-related mismatch losses can be reduced by an inverter's usage of

maximum power point tracking (MPPT)[32 Erko]. The primary factors that account for losses in
PV power systems are inverter loss (99 percent) and PV module loss (98 percent). The PV
array's output power after losses can be calculated using the following formula.

𝑇ℎ𝑒 𝑜𝑢𝑡𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟 𝑜𝑓 𝑃𝑉 = 6,177,350 ∗ 0.98 ∗ 0.99 = 5,993,264.97W

For this study, a 6MW DG was selected. Following the selected DG size, cost estimation was
done.

Table: Selected PV module type and its price

S/N PV module type Quantity Unit price per Total wattage Total
watt required price
($) ($)
1 Suniva ART245-60-3-1 PV 25,768 6,000,000

B. Size of an Inverter
For grid-connected systems, the input rating of the inverter should be comparable to the rating of
the PV array to enable safe and efficient operation(Ndagijimana & Kunjithapathan, 2019).

Consequently, the inverter's input power rating must be 6MW. For this study, since it is suitable
with design and has high power starting capacity, the central inverter PVS800-57-1000KW-C
made by ABB was selected [32Erko].

The efficiency, power quality, and lifetime must be taken into account when choosing a solar
inverter, and the detailed characteristics are shown in Table 3.10.

Table 3.10: Technical specifications of the chosen inverter. [25Erko].

Inverter model:- PVS800-57-1000KW-C

DC Inputs
Maximum input power ( P PVmax) 1000KW
DC voltage range (V mpp DC ) 600 to 850V
Maximum DC voltage (V max DC ) 1100V
Maximum DC current ( I max DC ) 1710A
Number of protected DC inputs 8 to 20(+/-)
AC Output
Nominal power( Pnom AC) 1000 KW
Maximum output power 1200 KW
Power at 0.9 pf 950 KW
Nominal AC current( I nom AC ) 1445 A
Nominal output voltage(V nom AC ) 400 V
Frequency 50/60 HZ
Maximum efficiency 98.8%
External auxiliary voltage 230 V, 50 HZ

Based on the design the overall power was grouped into three fields. Each field has a 2 MW
power capacity. Primarily, the calculations for one field has been done, which is then generalized
for the remaining fields. Given that the maximum power of each module is 240 W, it is simple to
determine how many modules will be needed in each field by:
 Rated power ( P rated ) per field
Number of modules per field ( N Tm ) =
Maximum module power ( Pmax )∗losses factor

2,000,000 W
¿ =8,590 modules
240W ∗0.99∗0.98

According to Table 4.2, the maximum power point voltage is between 600 and 850 V, while the
highest permitted DC input voltage is 1100 V.

To finding maximum number of series-connected modules per string that can be connected to the
inverter, both the maximum power point and open circuit voltages listed in Table 3.10 above
should be taken into account. Therefore, maximum possible modules per string can be obtained
as follows:

M aximum voltage of the inverter(V max ) 1100V

M odules per string= = =29.4 ≈ 29
open circuit Voltage (V oc ) 37.4 V

Therefore, 29 modules are the most number of modules allowable for series connections. It is
important to consider the short circuit and maximum power point currents into account when
determining the maximum number of parallel strings.

The quantity of strings is determined as follows:

I max Inverter 1710 A

Stringmax number/ inverter = = =205.3 strings
I Sc module 8.33 A

This indicates that the input of the inverter can support up to 205 parallel strings. The total
number of modules per field to be 8,590 modules, which will be distributed between two
inverters, will be taken into account for each inverter.

This implies that 4,295 modules will be linked to each inverter. Assuming that each string will
include 29 series modules for improved performance and security, the number of parallel strings
is then calculated as follows:

Total module String per inverter 4,295

Number of String/inverter= = = 148.1 ≈ 149 < 205.3
Maximum modules per string 29
strings
According to the previous calculation, the design uses 149 strings of 29 modules each while
respecting to the inverter and module standards.

As a result, (X?) inverters with a 1000 kw total output are needed.

C. Battery Sizing

The basic goal of battery bank sizing is to obtain an energy source that can handle the load
generated by the PV panel array and supply enough stored power for needs when there is no
sunlight.

E Tot (Wh)∗G ft
¿ the battery=
V dc∗DODmax∗ηinv

Where,

ETot (Wh)= Total energy (Wh)

DODmax = Maximum depth of discharge

V dc = Maximum DC System Voltage

Gft =¿ Grid failure time

ηinv = Inverter efficiency

Let’s assume the battery supplies the grid during failure for 4 hours. So that ETot =6MW*4=
24,000,000wh, DOD =0.7, because DOD of the lead acid storage battery is 70%, and Gft = 4/24
hr.

¿ E Tot (Wh)∗G ft 24,000,000 Wh∗4

Then , battery = 24 hr = 120,250.12 Ah
V dc∗DOD max
48∗0.7∗0.99

For this study, Lead acid batteries with product number of S1900 and 12V/2900Ah battery was
chosen. The design-rated power of the battery is assumed,

Total battery bank capacity 120,250.12 Ah

Total b atteries required= = =41.46 ≈ 4 2
capacity of chosen battery 2900 Ah
Depending on the voltage that the solar system generates, the battery bank system voltage may
be 12 volts, 24 volts, 48 volts, or 96 volts (Ndagijimana & Kunjithapathan, 2019). In this study,
a system voltage of 48 V was selected.

System voltage ( V s ) 48
Total number of batteries∈ series ( N bs ) = = =4
battery voltage ( V battry ) 12

Total number of batteries ( N bt ) 42

Total b atteries∈¿ ( N bp )= = =10.366 ≈ 11
Number of batteries∈ serie ( N bs ) 4

D. Charge Controller Sizing

A charge controller's function is to control the charge that enters the battery bank from the solar
panel array, prevent overcharging, and reverse current flow at night. The most popular charge
controllers are maximum power point tracing(MPPT) or pulse width modulation (PWM).

A MPPT solar charge controller will automatically and effectively convert the lower voltage
panels, battery bank, and PV charge to be equal in voltage when it detects a difference in voltage.
The size of a series charge controller is determined by the total PV input current given to the
controller as well as by the PV panel layout (series or parallel configuration).

In this PV module type, the short circuit current is 8.33A.

Charge controller rating=Number of∥modules∗Module short circuit current∗Safety facto r

I rated =N P PV ∗I sc∗1.3 = 781∗8.33∗1.3=8,426.99 A ≈ 8,427 A

Here, 48v, 30amp charge controller is chosen from the manufacturer's plate, and total number of
charge controller is calculated as follows,

charge controller rating

Total number of charge controller = =8,427A/60A? =
Amperes of individual controller

4. Cable sizing

4.1 Cable sizing between PV modules

The system was designed with a maximum cable voltage loss of 5%, which allowable with international
requirements for the maximum permitted voltage drop.
The following details are used to size the cable: The length of the cable is 1.5 m. The maximum current
that can pass through the wire is determined by:

I max=1.25∗I sc module= X A

Whereas, 1.25 was taken into account for security reasons. The maximum permitted voltage drop
can be determined by:

V mpp module∗5 %=Y V

The wires are classified as copper wires with a resistance of 0.0183 Ωmm 2 /m, and the cross
sectional area is calculated as follows:

2∗p∗l∗I max 2
A= =B mm
V dc max

For the wiring between PV modules, any cable with a cross-sectional area more than 0.38 mm 2 is
acceptable. However, while this number is adequate to ensure the least amount of voltage drop, it
is insufficient to guarantee that the wires can withstand the greatest amount of current passing
through them.

According to the NEC standards for cable sizing, a 1.5 mm 2 wire is required to withstand a
current of 9 A, while a 2.5 mm 2 wire is required to withstand a current of 16 A. In our case, a 2.5
2
mm wire is the best option because the maximum current with safety factor is 10.55.

4.2 Cable size from the PV array bus-bar to the inverter

The following details are used to size the cable: The maximum current from the array is 8.44 * 160 *
1.25 = 1688 A, and the wire is 20 meters long. The highest voltage drop is provided by:

Vd=5 %∗V DC min ( 600 ? )=Z V

The minimum cross sectional area of the cable is found by:

2∗p∗l(20? )∗I max (fromarray ) 2

A= =W mm
Vd

Therefore, 41.2 mm 2 of cable cross section is the minimum required to provide an acceptable voltage
drop; nevertheless, the design must take into account the cables' ampacity.
According to the cable tables, the largest cable size is 240 mm 2 and can take a maximum current of
400A for the wires, which must manage a current of 1688A. 6 wires of 150 mm 2 that can carry a
maximum of 1722A were found to be a good choice of cables.

Table 5.13: Detailed price of the selected PV and its components(Yishak)

S/ Quantity Unit Per Total

N List of Components Price Price
[ETB] [ETB
1 Module (250 Wp)
2 400kw inverter
3 Cabling, Switch, Holder, Plug, Divider and PV panel
support structure cost
4 Direct cost of equipment
5 Installation cost (7%) of direct cost of the equipment
Total system cost

For cost analysis and payback period Erko’s paper is very important.