Powering pharmaceutical with solar

Designing a complete 3D model of factory site and simulating whole project in a software, while installing the solar plants on its TIN shed roof.

In today’s cut-throat competitive market, delivering a good quality product at an affordable price is a big challenge. We closely work with many solar EPC companies as their design partners. To deliver a cost-effective and energy-efficient solution solar project design plays a very important role. Every site comes with a new unique challenge and new opportunities that excite us more.

One of our pharmaceutical industry owners from Vadodara wanted to go solar. He has an average consumption of electrical energy of 33,300 kWh per month which costs him approx ₹ 2.5 lakhs per month and he noticed a continuous increment in energy charges every year, and finally, in June 2019 they decided to install solar panels on his pharma factory.

We met the client to understand their exact needs and did a detailed discussion. In conclusion of the meeting we found the following major challenges:

• ROI time of the project should be less than 4 years.
  a. Minimum project cost
  b. Maximum energy generation
• Minimum roof space should be occupied.
• Maximum strength & stability which can sustain with heavy winds.

After realising these challenges, we visited the site. The rooftop of the industry was basically divided into two parts:

• RCC building, and
• TIN shed having slope toward east and west (5 degrees).

To meet the above challenges, we worked on the selection of technology, project feasibility. We found that there are ventilators and few other objects which will cast a shadow on solar modules in the morning and evening time for a few months of winter. For us, each ray of sun is very important and we wanted to get maximum radiation on solar panels.

TIN shed of factory RCC building of the factory
To get maximum generation we can use MONO PERC panels, which requires less space and produce more energy at the same time. MONO PERC modules cost a lot more. We studied the detailed datasheet of solar cell and choose modules in polycrystalline technology and fill factor of 79 percent. Poly 325-watt modules were good enough, in terms of both cost-wise and efficiency-wise.

Now the concern was space. Poly panels occupy more space, and will cover almost complete RCC roof and TIN shed roof. The customer did not agree to cover the entire RCC roof; they wanted some space for future construction on RCC. Though it was a minor shadow, we did not want to install solar panels in the shadow region on the TIN shed, because, we know that it affects the generation of an entire row of panels which was definitely going to increase the ROI time.

We designed a complete 3D model of the site and simulate complete project in software. We observed that we install the maximum project on the TIN shed; we will lose 5 percent to 7 percent energy because of the shadow of air ventilator. We obviously cannot remove the air ventilators of the industry. Hence we started looking for the best options for the inverter which should have a maximum number of MPPT, and maximum conversion efficiency. We were getting a maximum of 8 MPPT Inverter for 126 KW project. We went a step ahead and decided to use optimiser which can provide an MPPT circuit per two solar panels which reduces the losses further. With SolarEdge Inverter, we can make a string of 34 panels which helps to reduce DC losses furthermore. Additionally, we can monitor each module’s performance from our IoT based remote monitoring system.

For the long life of the structure, we designed a complete Nut-bolting structure of HDGI material. Our structural engineer has simulated the design in Staad.pro software and gives assurance of 150kmph withstand against winds.

Similarly, we measured earth resistivity and designed the grid of earthing in such a way that enabled us to achieve very low resistance (< 0.3 ohms) with less number of earthing rods. We calculated detailed losses of AC cable and chosen to optimize size and type.

Heaven’s EPC team Heaven’s design team
Once got final approval from the design team, we sat in a meeting with the EPC Company and the industry owner. Explained technical details of the project. He was very satisfied with this kind of deep analysis and optimized solution of the solar power plant. He gave approval for further installation. We prepared all the electrical drawings for CEI approval and submitted it to the DISCOM. We prepared complete BOM and working drawings for the installer.

3D design and real Installation
Finally, the project got installed as per the drawings and commissioned recently. Our team inspected the site and verified the electrical parameters. The plant is working as expected and hopefully, ROI will be done before 3.75 years. This project helped us to build stronger business relations with our client EPC company.

Project summary
No Solar power plant size 126 KW On grid

• Solar Panels HAVELLS 325 WATT
• Solar Inverter SolarEdge 82 KW & 27KW
• Optimizer SolarEdge P700
• Solar DC cable 1100 V Type-1 4 sq mm Polycab
• AC cable 3.5 C x 240 Sq mm AL. XLPE. ARMD
• Earthing 50 mm DIA- Hollow HDGI with chemical earhing
• Lightning arrestor ESE type – Level -I
• Structure Nutbolting type – HDGI

Visit us at
www.HeavenSolarEnergy.com
Email: Design@HeavenSolarEnergy.com