Chapter division of real on-site work steps for on-site debugging of PV side of photovoltaic power station
Phase 1: Commissioning team preparation and safety lockout (Day 1 morning)
Step 1.1: Review the calibration list of debugging instruments and tools (multimeter, megometer, phase sequence meter, clamp meter, infrared thermal imaging camera, torque wrench and calibration validity period)
Work step 1.2: PPE (personal protective equipment) equipment and arc protection confirmation for high-voltage/high-flow operations
Step 1.3: Start the on-site LOTO (Lockout/Tagout) safety isolation procedure and sign the Permit to Work (PTW)
Step 1.4: Review the as-built drawings, relay protection setting sheets and grid code parameters
Phase 2: Photovoltaic array and DC/AC side cold static test (Day 1 afternoon ~ Day 2)
Step 2.1 [Array area]: 100% blind test of the positive and negative polarity of the string (actual measurement with a multimeter to prevent reverse connection) and 100% verification of the Voc open circuit voltage
Step 2.2 [Array area]: Random test of string short-circuit current (Isc) and IV curve (≥10% random test, STC condition conversion comparison)
Step 2.3 [Array area]: DC string-to-ground insulation resistance (Riso) test (1000V/1500V megger test, impedance ≥ 2.0/5.0 MΩ)
Process step 2.4 [array area]: 100% extraction and review of component clamps, brackets and ground terminal bolt torques, 100% spraying of CoreTect anti-loosening marking lines
Work step 2.5 [Power distribution area]: DC/AC combiner box anti-condensation heater test, aR fast fuse resistance test at both ends and SPD lightning protection remote signaling trigger test
Step 2.6 [High-voltage area]: 35kV high-voltage AC cable megger insulation test (≥1000 MΩ) and power frequency withstand voltage (Hip-Test) test
Stage 3: Electrify the station power supply and control center (Day 3 - energize the "brain" first)
Step 3.1: Close the AC 380V/220V auxiliary power supply for the station, and check the auxiliary voltage deviation (within ±5%) and phase sequence
Step 3.2: Close the station DC panel (DC 220V/110V) and UPS, and test the stable output of the control power supply and the battery float voltage
Step 3.3: Activate the fire main screen (FACP) and security monitoring system to confirm that there are no fire alarms or intrusion alarms
Step 3.4: Start the SCADA background monitoring server, network switch and weather station sampling module (irradiance, shutter, plate temperature, anemometer)
Stage 4: High-voltage booster station and box-type transformer receive power (Day 4 - high voltage is supplied to the "blood vessels")
Step 4.1: Check the SF6 pressure gauge of the 35kV switch cabinet (green zone 0.35~0.45 MPa) and the three-phase anisotropy of the vacuum circuit breaker (< 1.0ms)
Step 4.2: Close the main circuit breaker of the 35kV booster station, conduct impact power on the 35kV high-voltage busbar, and check the three-phase voltage balance and positive phase sequence
Step 4.3: Gradually close the load switch on the high voltage side of the local box transformer to receive power from the box transformer.
Step 4.4: At the AC input end of the inverter, measure the low-voltage AC voltage (such as 800V AC) output by the box-type transformer and the A/B/C three-phase sequence.
Stage 5: Inverter power-on, grid-connected phase locking and SCADA P2P calibration (Day 5 - Node connected to the grid)
Step 5.1: Close the AC side circuit breaker of the inverter, and the inverter AC adaptive phase-locked loop (PLL) completes the grid voltage locking
Step 5.2: After checking the DC polarity for the second time, close the DC side switch of the inverter
Step 5.3: Connect the mobile APP to the inverter and load the Philippine local grid code (Grid Code, such as Philippines_NGCP 60Hz) and over-under voltage/over-under frequency parameters.
Step 5.4: Start the inverter self-test countdown (60~300 seconds), close the relay, and start the inverter to connect to the grid to generate electricity.
Step 5.5 [P2P comparison]: Under full power, use a Fluke clamp meter to measure the AC and DC voltage and current of the inverter, and compare it with the SCADA monitoring interface (error ≤ ±0.5%)
Step 5.6 [Emergency Stop Test]: SCADA issues a 50% power derating command and an "emergency stop" command to test the inverter response time (< 100ms)
Phase 6: Scheduling response, network planning test and full load scan (Day 6 - system joint debugging)
Step 6.1: Simulate power loss in the power grid, test the inverter anti-islanding protection (Anti-Islanding), cut off the grid connection and alarm within ≤ 2.0s
Step 6.2: Test scheduling AGC (automatic power generation control) active power tracking accuracy (≥ 99.0%) and AVC (automatic voltage control) reactive power adjustment
Step 6.3: After the entire station has been running at full power for 2 hours, use an infrared thermal imaging camera to conduct a thermal imaging scan of the MC4 connector, circuit breaker copper bar, and high-voltage cable head.
Phase 7: 72-hour trial operation and completion signed delivery (Day 7+ - stamped delivery)
Step 7.1: Start a 72-hour continuous trouble-free trial operation (no primary/secondary tripping, nothing more than planned disconnection)
Step 7.2: On-site calculation and qualification determination of PR (Performance Ratio) energy efficiency ratio of the whole station (PR of the whole station ≥ 82.0% under standard lighting)
Step 7.3: Organize and sign [Four sets of on-site commissioning delivery form packages] (the owner, EPC construction party, and CoreTect commissioning party stamp and sign)