IEC 62253 Edition 1 0 2011 07 INTERNATIONAL STANDARD NORME INTERNATIONALE Photovoltaic pumping systems – Design qualification and performance measurements Systèmes de pompage photovoltaïques – Qualifi[.]
Terms and definitions
PV converter
The PV converter transforms the direct current (DC) voltage generated by the photovoltaic (PV) system into either a higher or lower DC voltage Additionally, it can convert this DC voltage and/or current into single-phase or multi-phase alternating current (AC) voltage.
NOTE the PV converter may also include equipment for MPPT, monitoring, metering and for protection purposes.
PV pump aggregate
The PV pump aggregate consists of the pump (centrifugal pump, displacement volume pump) the driving motor and control
PV pump terminal cable
A PV pump terminal cable connects the PV converter and the pump aggregate
PV pump systems
A PV installation is comprised mainly of the following components and equipment:
PV generator, cabling, control unit (e.g inverter, DC/DC converter, etc.), motor, pump and hydraulic piping
Photovoltaic pumping systems in stand-alone operation
Photovoltaic pumping systems in stand-alone operation are photovoltaic pumping systems with no connection to the grid
Impedance matching
DC/DC Converter, which may include MPPT or V/I tracking maybe with temperature correction
System-types and -parameters
For the purposes of testing, PV pumping systems can be divided into four categories as shown in Table 1 The measurement access points within the system define these categories
Figure 1 illustrates the four basic arrangements, and defines the parameters that can be measured at each accessible point in the system The parameters are defined in Table 2
Table 1 – Categories of PV pumping systems for the purposes of testing
A DC systems either directly connected or with a control (impedance matching) electronics integral with motor-pump
B DC system with separate impedance matching unit, connected to either brushed or electronics commutated motor-pump unit where the corresponding controls are integral with motor-pump
C DC system (brushless) with separate commutation control (and impedance matching)
D System with DC/AC inverter for operation of a standard AC pump-motor
Figure 1 – Schematic of system types for the purposes of testing
(In case C, Vm and Im may be electronically commutated voltage and current)
Table 2 – Definition of the parameters
3 Generator open circuit voltage DC Voc V
4 Generator short cut current DC Isc A
5 Generator maximum power point voltage DC Vmpp V
6 Generator maximum power point current DC Impp A
9 Motor voltage DC or AC Vm V
10 Motor current DC or AC Im A
11 Motor voltage (multi-phase AC) V rms V
12 Motor current (multi-phase AC) I rms A
14 AC frequency (or DC switching frequency) f Hz
16 Torque at motor-pump coupling T Nm
General
Typically a PV pumping system consists of the following main components:
• Electronic converters which are separate (impedance matching device or inverter)
Relations to other standards
PV pumping systems are one of the applications for photovoltaics Therefore existing standards for the components shall be applied
PV modules must adhere to specific standards, including IEC 61215 for crystalline modules and IEC 61646 for thin-film modules, along with safety requirements outlined in IEC 61730-1 and IEC 61730-2 Additionally, the installation of PV generators should follow IEC 62548 guidelines It is crucial for the PV generator combiner box to display a warning label, indicating that its active components may remain live even after disconnection from the converter.
As PV pumping systems are stand-alone systems IEC 60364-7-712 applies as well
The PV generator combiner boxes and switchgear assembly for the PV converter installation must adhere to IEC 60947-1 standards It is essential to include a warning label indicating that fuses or disconnect devices on the DC side should not be removed or switched while under load.
Power Conditioning Units (DC-DC converter, DC-AC converter) have to fulfil the requirements given in IEC 62109-1
When selecting electrical equipment for the DC side, it is crucial to ensure compatibility with direct voltage and direct current PV generators should be connected in series, adhering to the maximum open-circuit voltage specified by the module manufacturer If blocking diodes are required, their reverse voltage must be rated at twice the open-circuit voltage of the PV generator under standard test conditions (STC) Additionally, refer to IEC 62458 for guidelines on PV installations.
The protection concept must adhere to the requirements for electric shock prevention as outlined in IEC 60364-4-41, ensuring the operational safety of the system Additionally, testing of electrical components and electronic devices should conform to IEC 60146, IEC 62103, and all applicable standards.
Lightning protection shall be compliant to the relevant standards and the requirements of
The damp-heat suitability of electronic apparatus shall be compliant at local ambient conditions to IEC 60068-2-30 (ref to damp-heat cyclic) 5 cycles shall be made for the electronic apparatus
Severity: With plants for tropical application the temperature amounts to 55 °C max
With plants in temperate climates the temperature amounts to 45 °C max
Protection against contact, foreign bodies and water shall be compliant to IEC 60529
Type testing of the transportability of electronic apparatus with packaging shall be compliant to
Assessment of immunity against conducted and radiated disturbing quantities shall be compliant to IEC 61000-6-2, IEC 61000-6-3 and IEC 61800-3
Pumps can be classified into 4 main categories, although supplementary types might exist
Centrifugal pumps shall fulfil the requirements given in ISO/DIS 9905 Class I
General
The system's performance can be assessed by evaluating it under different conditions, either in a laboratory setting, which ensures replicability and reproducibility, or in real-world field conditions for acceptance testing Either approach is sufficient for a comprehensive evaluation.
Test set-up
The minimum requirement for a test set-up for performance measurement is defined as follows
(Maximum measurement uncertainties are given in Table 4):
A real photovoltaic (PV) generator equipped with irradiance and wind measurement is essential for field acceptance testing, while a programmable PV solar generator simulator allows for the simulation of various PV configurations, including the number of modules and their series/parallel combinations, making it ideal for laboratory testing.
• Real cable type, length and diameter (for field acceptance or laboratory test) or Cable impedance simulator (for laboratory test)
• Measurement equipment with acceptable accuracy and precision for detection and registration of the parameters listed in Table 2
• Pre-pressurised air chamber (where the pressure level can be adjusted)
An example test circuit schematic is shown in Figure 2
NOTE Any equivalent test circuit (e.g for different pumping types) verifying correct hydraulic characteristics and system performance can be used, provided that it ensures the required initial counter pressure
The pipe connecting the pump outlet to the pressure sensor must match the diameter of the manufacturer's outlet fitting It is generally assumed that the pressure drop from frictional losses in this section is negligible during normal pump operation, and that the kinetic energy of the water at the outlet is minor compared to the potential energy increase from the pump's pressure However, these assumptions should be validated, and any necessary adjustments to the hydraulic power calculations should be documented in the test report.
The general layout of the system pipe work should be designed to avoid airlocks
For instantaneous performance testing, pressure can be maintained using a simple gate valve that restricts flow to create backpressure Alternatively, pressure sustaining valves are available to maintain a constant upstream pressure, though their performance may be unpredictable More advanced test laboratories may utilize a pre-pressurized air chamber with a pressure maintaining valve at the outlet or a real water column for pressure sustenance.
For accurate laboratory measurements with a flow meter, the discharge pipe's end must be submerged to prevent splashing, which can introduce air bubbles into the pump inlet and disrupt its function In contrast, when using the bucket and stopwatch method, the discharge cannot be submerged; therefore, a vertical baffle should be installed in the tank between the pump intake and return pipe This design forces water to flow beneath the baffle near the tank's bottom, effectively excluding small bubbles that tend to remain at the surface.
Alternatively a large pipe can be placed around the pump with its top breaking the surface and an arch cut in its base to allow water entry
10 m hose ( for induced flow pumps )
Figure 2 – Example of PV pump test circuit in the lab
Pumping system performance tests
General
The characteristics outlined in the component and implementation specification will be verified through performance tests, where components or subsystems undergo various procedures to ensure they meet the specified criteria A preliminary design check will follow the determination of performance curves, allowing for a comparison with the plant's required design data Additionally, the overall system data will be validated on-site through a field performance test, which provides essential information and performance curves that serve as the foundation for this evaluation.
Laboratory performance test: A schematic of the required laboratory system test circuit is shown in Figure 2
The converter efficiency test is performed according to IEC 61683:1999 and therefore not detailed in this standard.
P-Q characterisation
Testing the performance of pumping systems at a constant head (H) while varying input power (P) is crucial for determining the resultant flow rate (Q) In the laboratory, we will establish the characteristic constant head (H) curves for power (P) in relation to flow rate (Q).
The following constant head (H) curves should be determined (unless the manufacturer defines the lowest allowed head different Then H 1 should be taken as H min ):
Figure 3 illustrates a centrifugal pumping system, highlighting that H max (Q = 0) represents the maximum pumping head for centrifugal pumps For other types, such as helical rotor pumps, H max is specified by the manufacturer as the maximum operational head This maximum head is determined at the highest safe motor speed or the maximum frequency provided by the converter, if it is lower than the safe motor speed It is essential to adhere to the safety requirements set by the pump manufacturer.
The pumping system shall be run at nominal speed for 5 min at low pressure respectively open valves in order to get air bubbles out of the test loop
The pressure is maintained at a constant level while measurements commence at the maximum pressure The system input power is systematically reduced in steps, and corresponding flow rates are recorded To achieve this, the I-V characteristics of either a PV generator simulator or an actual PV generator, as outlined in the system design, are utilized A minimum of five measurement points, with equal differences in flow rates, is established between the highest and lowest input power levels This process generates a single P-Q curve for a constant pressure, represented in meters of water head.
Power vs flow rate for constant water head for a centrifugal pump with H max (Q = 0 m 3 /h) = 100 m at rpm max = 3 900
For field application a simplified procedure is applied:
The PV pumping system is set up at the chosen site, where a pressure sensor is placed in the well to measure the actual water pumping head H [m], which includes both static and dynamic components The flow rate of the pumped water Q [l/s] is determined using either a calibrated flow meter or the bucket method described in section 5.2 Additionally, the input parameters of the converter include the DC voltage V [V] and current I.
[A] are measured With these measurement the efficiency of the converter-motor-pump subsystem can be calculated (g = earth gravity = 9,81 m/s 2 ):
H-Q characterisation
In this characterisation the systems power is varied so that the pump runs at a set speed
The characterization of parameter \( n \) must include a speed that corresponds to the manufacturer's measured data, specifically for a.c pumps, which is linked to the inverter output frequency In the U.S., this frequency is 60 Hz, while in the EU, it is 50 Hz.
• Initially the pumping system shall be run at nominal speed for 5 min at low pressure with open valves in order to get air bubbles out of the test loop
The valve is adjusted to ensure the pump operates against its maximum head; for centrifugal pumps, this means the valve can be completely closed, while for displacement pumps, the valve is partially closed to achieve the rated maximum head.
• From this point the valve is opened in steps so that the maximum flow is reached
To maintain the desired speed at each new point, it is essential to adjust the input power accordingly (parameter n) This adjustment relies on the I-V characteristics of either the PV generator simulator or the actual PV generator, as outlined in the system design.
To establish a single H-Q curve for constant speed, it is essential to take at least five measurement points for equal delta flows between the closed and opened valve, despite variations in voltage and current.
• This procedure is repeated for other speeds A set of 5 curves should be taken where the speed difference corresponds to 5 Hz
Figure 4 shows an example graphic presentation
Speed 2 Speed 3 Speed 4 Speed 5 Speed 6
Figure 4 – Example of an H-Q diagram for the same pump at different rotational speeds
Start-up power measurements
This test determines the minimum power required to initiate a photovoltaic pumping system It is important to note that this test is no longer applicable for centrifugal pumps unless a non-return valve is installed.
The pump is turned off, and the pre-pressurized air chamber is filled to 50% with water Air pressure is then applied until the system reaches the pump's nominal head Additionally, the pressure-sustaining device, such as a pressure-controlled valve, is adjusted to match this head value.
The PV generator simulator is initialized at a maximum current value corresponding to the irradiance level, and the system is activated This process is conducted incrementally from low to high values until the system successfully starts, operates stably for 2 minutes, and remains without tripping This establishes the required startup power for the specified head.
For displacement pumps, the procedure is similar to that of centrifugal pumps; however, each startup test creates a water film between the rotor and stator that acts as a lubricant, reducing friction and startup power Since there are several hours between shutdown and startup, it is advisable to wait at least 2 hours between startup tests for helical rotor pumps to allow the water film to re-establish.
6 Design qualification for a pumping system
General
Effective planning of solar energy pumping systems necessitates the availability of comprehensive data It is essential for customers to provide sufficient information to the planner, while the planner must also rely on accurate data from component manufacturers.
This clause gives a guideline on how to properly design a solar pumping system for optimized operation.
Customer data
Longitude and latitude pinpoint the exact location of the system, while topography influences local conditions such as the generator's orientation in azimuth and elevation, as well as shading and air quality factors like humidity and dust levels Additionally, climatic data plays a crucial role in assessing these environmental influences.
– Irradiation: Design basis: IEC 61725 NASA data
If there is no data given by the customer, use the default irradiation data of
– Temperature data: average, min, max
If there is no data given by the customer, use the default average ambient temperature of 30 °C
– Maximum and average wind speed c) Specific local conditions
– Well data or data of the water source:
• well depth (static head), well diameter;
• well productivity (Q max in m 3 /h and total pumping head at this level) and evidence of well suitability;
• dynamic water level (the well output is determined according to international or national regulations);
• TDH (total dynamic head, including the friction losses of the piping system);
• required daily water supply under defined worst condition (irradiance, date, water head)
For adjusting the pressure in the pre-pressurised air chamber, also see Table 3
Water quality shall be according to international or national regulations, indication of dirt or sand particles d) Water demand
– Required daily water supply under defined worst condition (irradiance, date, water head) as Q d in m 3 /day
– Site description (including photographs where available)
– Type of site with height data for the determination of the total pump head, TDH, piping systems, (length, diameter)
– Vegetation with regard to shading
– Water tank, other distribution or storage facilities including technical specifications
The required data supplied by the customer leads to diagrams 1 and 2 and to the value v
(average daily pumped water) of Figure A.1 (example for a direct coupled PV centrifugal pumping system) This is the basis of the design performed by the systems supplier
Table 3 – Pressure in bars for equivalent heads of water
For templates for the capture of data, see Clause A.2.
System characteristics
(See the example of a centrifugal pumping system in Figure A.1 for further details.)
From the available data the system supplier defines the following plant characteristics:
• Dynamic pump head H including pressure losses due to pipe friction, measuring appliances and well draw-down over volume flow Q (see curve 1 in Figure A.1)
• Solar irradiance profiles (see curve 2 in Figure A.1)
The power characteristics of a photovoltaic generator are influenced by irradiation levels and the operational temperature of the PV module cells, as well as the angle of the generator's setting To illustrate this relationship, the power curve should include at least four key points: G max, 0.8 × G max, 0.6 × G max, and 0.4 × G max.
The PV-generator is characterized by its electrical output P in relation to irradiation G, derived from the maximum power points (MPPs) at different irradiations and module temperatures under specified limiting conditions It is essential to reference the limiting conditions, such as air temperature and wind speed, used by the manufacturer to establish this characteristic Additionally, any potential deviations of the converter from the MPPs must be considered when presenting the PV-generator's performance.
When using direct-coupled DC motors, it is essential to align the generator characteristics with the motor's operation Additionally, the open-circuit voltage (Voc) of the photovoltaic (PV) generator must be taken into account, ensuring that the open-circuit voltage (Uoc) remains less than the maximum voltage (Umax) of the converter electronics under all ambient conditions.
• The volume flow rate should be stated for the course of irradiation and for these plant characteristics It shall be defined by at least four points (G max , 0,8 × G max , 0,6 ×
• The integral of the flow rate graph represents the quantity of water pumped daily This value should meet the value of the required volume within a tolerance of –5 % to +20 %
During system dimensioning, it may become clear that achieving an optimal design within –5% to 20% of daily requirements is unfeasible due to discrete design parameters, such as the number of strings In such cases, it is essential to reach an agreement with the operator and, if necessary, adjust the operator's criteria.
Dimensioning of hydraulic equipment
Pressure loss calculations need not be made if the following dimensioning criteria are fulfilled:
To ensure efficient system performance, piping must be sized to limit friction losses to a maximum of 5% of the total dynamic head at standard temperature and pressure (STC) Additionally, the nominal flow rate of water meters should be at least 1.5 times the maximum volume flow rate.
Documentation
General
The documentation will serve as a reference for the design process, detailing the data and assumptions that informed the design It will also outline the procedures used and specify measures for safe, sustainable, and environmentally friendly operation This documentation will be essential for discussions if the installed system fails to meet the required standards.
Operating and maintenance handbook for the pump maintenance staff
This document shall contain easily comprehensible descriptions with simple figures covering the following topics:
• Standard operational procedures such as start-up and shut-down
• Functional description, description of functional supervision and interpretation of status and error indicators
• Rules for action on faulty operation
• Personal safety behaviour, protection against electric shocks
• Maintenance work such as cleaning
A logbook should be established in order to gain continuous operation information The document shall be written in the language common to the country and in English.
Maintenance handbook covering operation, repair and servicing
This document shall contain easily comprehensible descriptions with simple figures covering the following topics:
• Operation and servicing instructions with details of service schedules, with start-up instructions and with troubleshooting checklists for the plant as a whole
• Schematic description in the form of an overview plan with references to the relevant detail plans
• Electrical circuit and regulation diagrams, implementation plans, wiring and terminal diagrams
• Parts list in agreement with the graphical documents quoting all the data necessary for an order
• Exploded drawings of the pump unit with particular attention paid to the labelling of working parts
The document shall be written in the language common to the country and in English.
Design check of the PV pumping system in respect to the daily water volume
For the given hydraulic characteristics of the system performance curve in the characteristics,
The performance characteristic curve of P over Q allows for the determination of volume flow rates based on the daily irradiation patterns and the output of the PV generator, in conjunction with the performance plant characteristics.
Dimensioning in the overall design is considered acceptable when the volume flow rates, as determined previously, exhibit a maximum deviation of -5% to +20% (including measurement tolerance) for the points G max, 0.8 × G max, 0.6 × G max, and 0.4 × G max, which correspond to the daily water volumes to be pumped.
Measurement is calculated using the individual tolerances of the sensors allowing for measuring transducer error The measurement should be defined to a maximum uncertainty of
In field applications, the subsystem efficiency calculated in section 5.3.2 can be utilized to verify the expected performance It is important to consider that the power output of the PV generator may degrade by as much as 30% due to factors such as elevated cell temperatures exceeding 70 °C, aging, and surface dirt accumulation.
Recording of the measured parameters
In all cases a laboratory logbook should be kept, in which all original measured quantities are recorded
Different system configurations require distinct measured parameters, as illustrated in Figure 1 (point D), and measurement capabilities vary across laboratories Therefore, it is recommended to establish a defined set of core and optional measured parameters for each configuration (A to D) Core parameters are essential for system characterization and can be measured with basic equipment, with all participating laboratories expected to measure them In contrast, optional parameters may necessitate more advanced measurement tools.
Table 4 summarises the core and optional parameters for each system configuration defined in
Table 4 – Core and optional parameters to be measured and recorded
No Parameter Symbol Unit A B C D Uncertainty
1 Generator voltage Va V Core Core Core Core ≤1 %
2 Generator current Ia A Core Core Core Core ≤1 %
3 Pressure as measured p bar Core Core Core Core ≤2 %
4 Flow rate Q m³/h Core Core Core Core ≤2 %
7 Motor voltage (multi- phase AC) V rms V Option ≤1 %
8 Motor current (multi- phase AC) I rms A Option ≤1 %
10 AC frequency (or DC switching frequency) f Hz Option Option ≤2 %
11 Motor speed n min –1 Option Option Option Option ≤2 %
12 Torque at motor-pump coupling T Nm Option Option Option Option ≤2 %
13 Water temperature (at inlet) t o C Core Core Core Core ≤2 %
Core Basic parameter that should be measured by all laboratories
Option Optional parameter that may be measured by those with the appropriate facilities
Uncertainty Maximum uncertainty of the measured value
Symbol Symbol of the SI units
Performance diagram, component characteristics and definitions
A.1 Diagrams to show system performance for centrifugal pumping system
Analytical expression for solar irradiation profiles
Hydraulic characteristic including friction losses and well draw down
For daily solar profiles IEC 1673/11
Figure A.1 – System performance for a centrifugal pumping system
A.2 Technical data, component characteristics (to be supplied by component manufacturers)
Number of modules (serial x parallel): _
IEC 61215, IEC 61646 and IEC 61730, Yes No
I-V characteristics of PV-generator at corresponding ambient temperatures (PV-module cell temperature) and irradiance levels
The output data must include mismatch losses It is essential to provide the PV-generator data for the anticipated ambient temperature range, specifically the PV-module cell temperature, while considering a wind speed of 1 m/s.
Output frequency range: _ Hz if applicable
Converter efficiency progression from 0,05 P N to P N (see IEC 61683:1999 Table 1)
Nominal voltage/frequency: _ V _ Hz (if applicable)
Power factor cos ϕ: at _ Hz (if applicable)
Max diameter and length of motor: mm
Pump head: range of operation: m nominal = _ m
Volume flow: range of operation: m 3 /h nominal = _ m 3 /h
Max diameter and length of pump: mm
Other specifications yes no Dry running protection:
3 Termes, définitions, types et paramètres de systèmes 30
3.1.3 Câble terminal de pompe photovoltạque 30
3.1.5 Systèmes de pompage photovoltạques en fonctionnement autonome 30
3.2 Types et paramètres de système 30
4 Exigences pour les composants du système 32
5.3 Essais de performance du système de pompage 35
5.3.4 Mesures de puissance au démarrage 38
6 Qualification de conception pour un système de pompage 38
The operational and maintenance manual for the pump maintenance team at the photovoltaic pumping site outlines essential procedures It includes guidelines on the functioning, repairs, and upkeep of the system Additionally, it addresses the design control of the photovoltaic pumping system in relation to the daily water volume requirements.
Annexe A (informative) Diagramme de performance, caractéristiques de performance et définitions 44
Figure 1 – Schéma de types de système pour l'essai (Dans le cas C, Vm et Im peuvent être des tension et courant électroniquement commutés) 31
Figure 2 – Exemple de circuit d'essai de pompe photovoltạque en laboratoire 35
Figure 4 – Exemple de diagramme H-Q pour la même pompe à des vitesses de rotation différentes 38
Figure A.1 – Performance du système pour un système de pompage centrifuge 44
Tableau 1 – Catégories de systèmes de pompage photovoltạques pour l'essai 31
Tableau 3 – Pression en bars pour des hauteurs de charges d'eau équivalentes 40
Tableau 4 – Paramètres principaux et facultatifs à mesurer et à enregistrer 43
SYSTÈMES DE POMPAGE PHOTOVOLTẠQUES – QUALIFICATION DE LA CONCEPTION ET MESURES DE PERFORMANCE
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La Norme internationale CEI 62253 a été établie par le comité d'études 82 de la CEI: Systèmes de conversion photovoltạque de l'énergie solaire
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SYSTÈMES DE POMPAGE PHOTOVOLTẠQUES – QUALIFICATION DE LA CONCEPTION ET MESURES DE PERFORMANCE
This standard outlines the design requirements, qualification, and performance measures for autonomous photovoltaic pumping systems The specified measures apply to both indoor testing with a photovoltaic generator simulator and outdoor testing using a real photovoltaic generator It is relevant to systems with pump sets connected directly to the photovoltaic generator or through a converter (DC-DC or DC-AC) However, it does not apply to systems that include an electricity storage device unless that device is solely used for starting the pump (less than 100 Wh).
The aim is to establish a verification procedure for the design of a photovoltaic pumping system based on specific environmental conditions This standard addresses the following design characteristics of pumping systems:
• Caractéristiques de puissance en fonction du débit à hauteur de charge de pompage constante
• Caractéristiques de hauteur de charge de pompage en fonction du débit à vitesse constante
• Paramètres et exigences de conception du système
• Procédure de vérification de la conception du système