REPORT OF PAKISTAN COUNCIL OF RENEWABLE ENERGY TECHNOLOGIES (PCRET)

EXECUTIVE SUMMARY:

Presently Pakistan is facing major energy crisis that has seriously affected the economic growth. Prolonged load shedding is a routine matter. The reason is continuous decline in gas and oil reserves and sharp increase in prices. The work on new multi-purpose dams / water reservoirs like Bhasha Dam have started which is a long-term process and does not provide an immediate solution to its water needs. Use of renewable energy technologies including “Photo Voltaic Solar Power” is an option that can be affectively implemented.

PV Systems are very popular in the western countries where sun irradiations are quite low as compared with Pakistan- being a Sun Belt Country. Solar energy is one of the cheapest and important ways to produce the energy. As per scientists, the energy received from the sun in one hour is more than the whole world’s total produced energy in a year. As per analysis if only half percent of desert land is used for solar energy it would cater the energy demand for this entire world. Pakistan has much potential for solar energy because Pakistan is receiving 19 Mega joules per square meter in a year through which 90% of rural area can be provided with the electricity.

Through out the developed world, Photo Voltaic industry has come a long way and grid parity is now within close reach.  In the years to come, activities in the solar market will form an important entree into the development of distributed power systems and the smart grid.In PCRET perspective a clear trend is seen towards a more decentralized generation of electricity in Pakistan as a developing and same has been seen in developed countries.

 

So far more than ten private sector companies with collaboration from abroad have taken start to install Solar Power Plants of capacity 2 MW to 50 MW in Pakistan. These parties have applied the NEPRA and Alternate Energy Board to acquire licence for installation of these plants in the country. Besides this, many of the individuals are looking forwards to utilize their rooftops for generation of Electric Power from Solar Energy. This means that the PV industry will face many more opportunities related to rooftops in industrial parks or even at the residential level in Pakistan like in the U.S.A, across Europe and Asia as well. Already, the Singapore government has begun second-phase trials of residential rooftop installations to save residential consumption upto 170 MWh of electricity each year.  The trials are part of a US$23 million program by the Singapore Government to reduce dependence on conventional electrical energy and bring about more sustainable development.

 

The next trend in the developed countries is the realization of microgrids which refer to a combination of different clean energy sources close to the consumption centers. PV installations are the first step towards the evolution of microgrids where energy is produced solutions for high-energy-use building clusters such as universities, R&D parks and manufacturing facilities. According to Pike Research’s Microgrids report, between now and 2015, more than 3.1 GW of new microgrid capacity will come online worldwide, representing a total market value of US$7.8 billion. North America is expected to capture at least US$5.8 billion, or 74%, of this market. In addition, more than 2,000 microgrid sites are expected to be operational worldwide by 2015, up from fewer than 100 in 2010.

 

PCRET also believes that large solar farms (PV Solar Panels installed on large areas on the ground) will continue gaining momentum and that they will get even bigger in the next five to 10 years. For instance, construction on the world’s largest solar farm with 73 MW in Thailand, costing US$250 million, is expected to commence next year. Such large-scale solar farms will begin to demand high powered inverters and more sophisticated monitoring and metering systems.

 

PCRET is dedicated to provide local national level organizations  with renewable energy alternatives, such as solar which will decrease environmental impact as well as reduce energy costs. PV power will become an increasingly widespread and a very important part of our energy infrastructure.In order to familiarizing and utilizing the renewable energy technologies of Photo Voltaic Solar Power, this project will set a trend for other public and private sector buildings to opt PV Systems in Pakistan.

 

Solar energy is available for more than 300 days a year in Pakistan with about 6-8 effective daylight hours.

Pakistan Power Sector:

• Current installed generation capacity: 22,500 MW of which, WAPDA (Hydel) 6500 MW, WAPDA (Thermal) 4900 MW, KESC 1950MW, IPPs 8363MW, Nuclear 787MW
• Current Power Availability: 17,000 MW Peak Demand 22,000 MW. Average shortfall 5000MW
• Electricity demand growing @ 10 % annually Vs supply @ 7 %.
• Resulting outages: Urban 7-10 hours daily, Rural 15-20 hrs daily
• Projected 2030 power requirement > 45,000 MW

Process:

Keeping in view increasing demand for solar energy in Pakistan, our company decided to expand its business from solar panel installation to solar panel manufacturing. After much research and development, we came to know PCRET and its 10 MW solar production line plant. This is closest to Aliaa-Alhijaz’s mission statement: to provide solar energy at reasonable cost and high quality. So we visited PCRET LABS and acquired data for our purpose, detail of which is given below.

Solar Cell:

Solar cell is basic unit of solar panel. It comes in different sizes. For example 0.6 Volts, 4.9 Watts, and 9.8 Amps. 0.6 V, 4.5 Watts, 7.5Amps. It is joined in series and parallel to obtain different voltages and current according to our requirement. Solar cell is pasted with silver lining and Aluminum alloy for tabbing.

Tabbing: is a means of attaching leads, or has leads for your electrical cell. Metallic tabbing ribbon pasted with flux material is placed on negative side of solar cell and then soldered with soldering machine. Extra ribbon is left along the length of cell for joining to other cell. It can be done manually or by help of automatic or semi automatic tabbing machine.

Keeping in view while soldering, there should be no bubbles in solder joint otherwise it would break while lamination process and whole cell would be defected/cracked.

Stringing: Connecting one cell with other in a string like fashion is called stringing. Leads from negative side of one cell are connected to positive side of other cell. It continues until required number of cells is arranged in a string. In this manner voltage of solar cells remain the same however current increases as number of cells increase. If we wish to increase voltage, we add or join cell in series.

Lamination: After stringing solar cells are covered with 1-EVA, 2- TEMPERED GLASS COATING 3-TEDLAR sheet. This whole assembly is placed in lamination machine, which has 3 chambers namely A, B and C. Each chamber process takes 15 minutes and then shifts the solar panel to next chamber. During the process glass and EVA material melts and sticks to solar cells like clear crystal glass.

Framing: When it comes out of lamination machine, its size is measured and accordingly it is framed with aluminum frames and adhesive material.

Testing: Solar panel is placed inside solar module test machine and it VI curve is observed on interface. Short circuit current and open circuit voltage values are compared with on load curve conditions. If there is any defect in panel, it would be highlighted by zigzag or obviated pattern of VI curve. EL-test of solar module undergoes to check the fault in solar module which can affect the output of solar module. EL testing shows the X-ray of whole solar module. If any solar cell of solar module is defective then it will be repaired by using repairing technique. Defective solar cell will be re-laminated to solar module after recovery.

Cost of 270 watt Solar PV Panel

Sr. No.	Component/Material/Items /Specifications	Quantity	Cost of Used to Produce Module in Rs.	Material cost of 270 watt Module in Rs.
1	A-Grade Mono Crystalline Solar Cell with efficiency > 18%	60 Cells	220.00	13200.00
2	Junction Box with Blocking Diodes and Cables	One	1200	1200.00
3	Al-frames Size 165.5 X 100.5 cm	One	2442	2442.00
4	Tempered Glass 165 X 100 cm	One	2500	2500.00
5	Tedlar Sheet	1.65 Sq m	1265 per Sq m	2087.25
6	Fast Curing E.V.A Width 2100 mm	3.3 Sq m	542 Sq m	885.00
7	Tabbing /Bus bar Material	143 gm 19gm          162gm	7200 kg	1166.40
8	IPA 2.5 liter	1 Bottles for Tempered Glasses cleaning	1600	16.00
9	Dichloromethane 2.5 liter	3600 Cells	1800	30.00
10	Flux	120 Panels	680	5.66
11	Magic Tape (M3)	30 Panels	110	3.66
12	Tissue Papers	08 Rolls	60	7.50
13	Electricity Charges per watt		540	2.00
14	Labor Charges		540	2.00
15	Testing Charges		1000	3.700
	Total Cost of 270 W Mono Crystalline Solar Panel			Rs. 25110 per 270 W A-Grade Solar PV Module
	Cost per watt of Certified and Warranted   A-Grade PV Module			Rs.93/- per Watt

 

COMPARISONS OF SOLAR PANELS/SOLAR MODULES

SOLAR PANELS/SOLAR MODULES MADE BY PCRET	IMPORTED PANELS/SOLAR MODULES
Type of Solar Panel	Type of Solar Panel
Mono Crystalline Cells	Mono Crystalline Cells
Wattage	Wattage
270 W	250 W
Efficiency/Grade	Efficiency//Grade
15% to 16.5 % (A and + A Grade)	15 % to 16 %  (A-Grade)
Warrantee and Life Cycle	Warrantee and Life Cycle
Warrantee at 92%  for 25 Years and life for 25 to 30 Years	Warrantee at 90 % for 10 Years and life for 25 Years
Cost Per Watt	Cost Per Watt
Rs. 93/- without profit	Rs. 115/- to 125/-

 

Key Equipment List:

• Automatic Laminator
• Automatic Framing Machine
• Solar Cell Tester
• Solar Module Tester
• Solar EL-Tester
• Testing table before laminating
• EVA/TPT cutting machine Table
• Cutting edge Table
• Fixed Laying Table
• Repair Table

Raw Materials:

• Cells poly & mono
• Frame kit with anodized aluminum
• Solar glass
• Back sheet EVA
• Ribbon
• Junction box
• Sealant
• Soldering wire
• Scotch tape
• Flux
• Packing material
• IPA (Tempered glass cleaning)
• Dichloromethane (cleaning of solar cells)
• Magic Tape

 

Cost Analysis:

Cost Comparison of PV Solar Panels and Selling Point: PCRET encourages the production of A-Grade Solar Panels only.

1. Cost of certified, imported A-Grade Panels (with out any firm warranty) is Rs. 110/- per Watt.
2. The PV Panels produced with Technology Transfer will be sold with 25 Years Warranty.

• The PV Panels produced with Technology Transfer by PCRET will be sold with individual Test Report traceable to PCRET Standards/ISO 17025/IEC 60904-9 AM 1.5 Class A etc.

1. Selling price of certified, locally made A-Grade Panels (with 25 Years warranty) is Rs. 100/- to 105/- per Watt.

Actual Cost Analysis: The actual cost depends upon the cost of imported cells and materials in bulk.

18. Presently Cost of the A-Grade Solar Cell (efficiency in the range 18.2 5 to 18.4 %) is around Rs.48/-per Watt*.
19. Cost of Materials is around Rs.28/- per Watt*.

• Cost of Workman ship is around Rs.10/- per Watt

1. Cost of Utility Charges is around Rs.2/- per watt.

(Total cost of manufacturing is Rs.86/- per Watt).

*          This is cost for quantity in Thousands it goes further 10 % to 15 % down when quaintly is in 100 thousands.

The Future of this Business: As this product is new and industry is growing slowly. Only three industries are presently producing very limited quantity of PV Solar Panels in Pakistan. These three industries are i).  M/S Tesla, Islamabad. ii). M/A Akhtar Solar, Hattar and iii). Nizam Solar, Karachi.  All of these three companies are heavily booked for their production orders and there is very big business opportunity in Pakistan to start this industry.

As the number of local industries is increased in Pakistan and a sizeable production is achieved, the Alternate Energy Development Board and Engineering Development Board will be bound to impose duty on the import of PV Solar Panels from abroad.

Mean while PCRET has sensitized the Alternate Energy Development Board to impose duty on all PV Solar Panels which are below the quality of A-Grade Solar Panels. This will help the local investor to take benefit of this offer of PCRET for transfer of technology of High Quality PV Solar Panels in Pakistan.

 

Main Items Used in 5MWp Solar PV Power Plant

List of items

Main item

No.	Item	Specification	Unit	Quantity
PV
1.1	Solar modules	250Wp poly	piece	20000
1.2	bracket	Concrete roof backet	kW	5000
1.3	AC pv combiner box with ligting protection	5 “in” 1 “out”	set	50
1.4	Solar grid tie inverter	20KW solar grid tie inverter	set	250
1.5	Grid tie cabinet	500KW	set	10
Monitoring system
2.1	Monitoring system	monitoring host, display, monitoring software	set	5
2.2	Mark meter	0.2s	piece	10
2.3	Environmental Monitors		set	10
Cable and etc..
3.1	Photovoltaic waterproof connector	MC4	couple	35000
3.2	DC cable	PV 1*4mm²	m	68000
3.3	AC cable	ZRC-YJV22-0.6/1KV-3*70mm²	m	12000
3.4	AC cable	ZRC-YJV22-0.6/1KV-3*10mm²	m	4500
3.5	Contril cable	ZRC-KVVP2-22-500 4*2.5mm²	m	1500
3.6	Cable tray	Galvanized bridge200*100mm	m	1550
		Galvanized bridge100*50mm	m	3000
3.7	Protective hose	DN25mm	m	5000
Lighting protection
5.1	Hot-dip galvanized flat steel	40*4mm²	m	8500
5.2	Grounding cable(yellow green)	YJVR-1*4mm²	m	8000
5.3	Grounding cable(yellow green)	YJVR-1*16mm²	m	2500

Concept of Frequency Drives to Reduce the Cost of Energy

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The task of a variable speed electrical drive is to convert the electrical power supplied by the mains into mechanical power with a minimum loss. To achieve an optimum technological , the drive must be variable in speed. This will adjust the speed o f the driven machine. This is ensured by the low loss control using solid state technology in electronic controllers.
The solid – state devices, which convert the AC supply to DC supply, were first used as
variable speed devices, in DC technology.
Using these devices the armature voltage of a
DC motor and therefore the speed can be
adjusted, almost without losses and over a
wide range of speed. Using these features the
drive can be designed which start smoothly
and jerk- free. This helps to maintain the
desired selected speed, independently of the load and operate with good dynamic response
The DC drive needs special consideration in some applications. For example in hazardous atmosphere, vibrations and higher speeds the usage of AC motor with squirrel-Cage rotor is advantageous. The use of frequency inverters (VFD’s) to supply to AC Motors resulted in a new orientation of electrical power. Every standard AC motor can be fitted with a variable speed drive using a frequency inverter. Frequency and voltage of the single – phase or three – phase mains are varied by the frequency inverter, such that the motor can be operated with varying speeds over large range settings. . Four–Quadrant Operation: A Four-quadrant diagram can represent mode of operation of variable speed drive. In Quadrant 1 the speed and torque can be represented positive or forward direction. This is consistent with a motor driving a load taking power from the mains. Similarly in Quadrant 3, both speed and torque are in negative or reverse direction. This behavior is known as Regeneration. After going, through the mode of operation ofVSDs,

Bsc Electrical/Electronics/Telecom Engineering Projects

Projects All around

Automatic Billing System Using Barcode Recognition (By Using PIC 18f4550):

Project is an attempt to develop an automated shopping billing system using bar code recognition and wireless transmission of total bill on counter. Theme of this system is to read bar code on different items. It starts adding the prices of items and deducts the total amount of the item if removed, and transmits the total bill to the counter using RF module APC 220. Prices will be added in to microprocessor memory (EPROM) along with shopping item names.

RFID Based Attendance System:

In this system, each student is issued an RFID tag. Controlling unit is in the institute. Whenever the card is placed near the reader, it will take the attendance.

Automated Car Parking System Using Motion Sensor:

 

The project of Instrumentation, by the using of Infrared the rays has been struck to the car and it detects the motion of car while going in to parking. On the large Basis we can accumulate it on RFID technology, which tends to increases the security issues also.

 

Water Level Controller using 8051 Microcontroller:

 

This system monitors the water level of the tank and automatically switches ON the motor when ever tank is empty. The motor is switched OFF when the overhead tank or container is FULL. Here the water level of the tank is indicated on LCD (Liquid crystal Display). Using this system, we can avoid the overflow of the water.

 

Inverter Overload Protector With Delayed Auto Reset:

The leading property from the domestic inverter is when the successive overload happens; it will cut off the Mains. When the system becomes stable within in seconds it will Auto reset after duration of 6 seconds by the use of buzzer. The main advantage is the cost which is being reduced.

Variable AC/DC Power Supply 60 volts:

 

With the use LM347 voltage regulator, the voltage being rectified and transformed through a transformer, which steps down the 220V to three different levels 48V-24V-12V. Then separate knob for each output by adding the different levels.

 

Mobile Detector Bug:

 

In this project, I used NPN BJT transistor which has an advantage of being high current can flow between emitter and collector. This is also used as switches the currents and when the currents switched buzzer being activated whenever the mobile being searched the bug as miscall or message

A Research Report on Integrated Service Digital Network (ISDN):

 

ISDN is the communication standard sets which are being used for transmitting and collecting data. It provides the high data transfer rates. Primary interface rate provides 1.544mbps. Now-a-days highly data transfer rates are achievable by this technology of networking.

Design of Electronic Pendulum:

 

This project accumulates the logic design and mechanics. IN914 silicon switching diode is used here which has been renowned for double plug construction. IC 74LS154 which enables only one output at a time, 555timer is used as Oscillator here.

 

 

 

AUTOMATED BILLING SYSTEM USING BARCODE RECOGNITION AND WIRELESS TRANSMISSION

 

OBJECTIVES Our aim is to develop the system which can be used in shopping malls to solve the problem of Queues. The system will be placed on trolleys in the mall. It will consist of Barcode reader. All the items in the mall will be equipped with Barcode tags. When person put any item in the trolley its code will be detected and the price of that item will be shown. As we put the items the costs will get added to total. Thus the billing will be done at the trolley itself. Item name and its cost will be displayed on LCD. For detecting different items Barcode reader will be used PIC microcontroller to store the Item specific number. LCD will be used to display item names and item cost. APPLICATIONS: Small Range Wireless System Wireless Data Transmission

Figure show components of projects

Future Work: This smart SYSTEM has wireless sensor networks. We are using RF transceiver module. In the future, all billing information in microcontroller can be send to central computer using various technologies like Bluetooth, GPS system or WIFI.