Topographically designed modules to sustain extreme weather

With the government’s push for achieving 175GW of renewable energy generation by 2022, India is willing to go solar, and have least dependency on fuel based electrical consumption. The industry leaders are trying to mull ways to withstand in difficult climatic conditions, with the help of solar.

Solar structures are the backbone of any solar PV energy project. Ensuring on possession of excellent quality mounting structures reflects the workability of any solar panel. They significantly help to withstand the weight of solar panels, high speed winds and varied temperatures, which plays a crucial role for countries that are prone to floods and natural calamities.

Mounting structures engineering to withstand harsh climate
Recently, severe flood pounced on Indian states causing immense dent to the lives and the state’s economy. Such calamities force us to consider on having solar structures installed in possible areas and households. Viewing the rising concerns of being hit by climatic conditions, Shashikiran NK, Managing Director, Arushi Green Energy (India) Private Limited, says “The purpose of building mounting structures is to withstand harsh climatic condition and extreme temperatures. After all they have to be built to last for the life time of a solar PV plant of 25 years, so the planning and procurement must aim on generating highly durable panel. Unless, the ration provided and the ration required for the climate is same, the module won’t withstand in extreme conditions.”
When it comes to structural requirement, the structure in rooftop segment is customised in line with the roof profile, its strength and the solar PV module used. Material used as standard practice is mild steel which provides strength and can be galvanised to prevent corrosion even in humid atmospheres. Shilpi Dangi, DGM Engineering, Gensol says, “These structures can be designed for utilisation ratio of 1.3. But for sturdiness, structures are designed with optimised UR to ensure sturdiness in case of severe winds considering climate change which is bringing a new seasonal pattern in most of the places. “Structures with aluminium rails are also used for some shed profiles and adoption of fibre reinforced polymer for its sturdiness is implemented in some cases successfully as well”, he added.

Maxson Lewis, MD, Magenta Power feels that most of the solar installers are not that keen about the mounting structures. Interestingly, solar panels and inverters come with 20+ years of extended warranties, but the same is not true about the structures. Continually ignoring the mounting structure, may result in degradation, further resulting in recurring costs. He says, “Using 3D simulation software for designing such structures is highly recommended. It is also important to choose structures of the right non-corrosive material from reputed manufacturers. Maintaining the structures is equally essential for longer shelf life.”

There are certain set standards, that must be followed while mounting a solar module. Talking on the same, Kuldeep Kumar Jain, BU Head of EPC, Vikram Solar, “For ground-mount projects, foundation mounting structures are common, but this depends on local climate, module size, and array tilt, among other factors. The installation tilt also plays a major role in protecting the solar plant through harsh climate conditions.” Moreover, customising the solar module structures, must be based on the topography of the land, module design, and the climate of the region.

Quality of module structures being compromised owing to low tariffs
Quality of the products is hampering the service deliverable. Discussing the same, Manoj Gupta, VP-Solar and Waste to Energy Business, Fortum India Pvt. Ltd, says, “Especially, the quality of solar cables and solar mounting structures are not of required standards, so as to sustain heavy climatic conditions. Low tariff is good from the consumer and industry growth perspective however quality and life of the project should not be compromised. Developers or EPC players while participating in the bids, should always account for the lifetime cost of their installation.”

Bharat Bhut, Founder, Director, Goldi Solar Pvt. Ltd, want these structures to be designed such that they are tall enough to withstand flooding conditions and strong enough to withstand strong winds and various other climatic conditions. However ,lately the quality of structures has taken a toll to reduce costs which has a negative impact on solar projects that are supposed to last 25 years in any weather. “It is a grim situation across the industry that companies are compromising on the quality of module structures which could collapse them and further resulting into a negative perception of the customers and investors regarding solar project investments,”Bhut adds.

Low tariffs have come into picture due to diminishing cost of balance of system products and PV modules in itself. However, Shashikiran, feels that developers considering cost cutting pertaining to low tariffs, may result in compromising in quality of structures. He says, “Performance guarantees/warranties contained in the agreements with providers/developers/contractors have a check on such practices. As of now, low tariffs have to some extent been matched by low module prices. So, the incidence of such compromise of quality will be very low or not significant.”

Cut-throat design adaptations along with low strengths material and lack of proper galvanisation have become prevalent in the market with, grievous outcome. Dangi on this note suggests customised mounting designs and says, “PV plant designs need customisation and general price perception should factor local installation concerns to ensure decent quality across the projects lifetime.”

Compromised quality, following low tariffs are unfortunately true for a lot of rooftop solar installations. Viewing it as a derailing component for structures, Lewis says, “A lot of consumers go through the tender route for identifying the right solar installer. The technical specifications listed in the tender covers the panels, inverters, wires and all electrical components in great detail. However, it does not cover the structural material in most cases, leaving this as an open area for installers to cut corners in.” A 25-year long-term investment, means that each and every component has to last for 25 years, should be replaceable easily and cost effectively.

Continually ignoring the mounting structure, may result in degradation, further resulting in recurring costs.
Maxson Lewis, MD, Magenta Power

Developers or EPC players while participating in the bids, should always account for the lifetime cost of their installation.
Manoj Gupta,VP-Solar and Waste to Energy Business, Fortum India Pvt Ltd

The mounting solutions have to consider whether the deployment area is flat, inclined or corrugated, made of concrete construction or metal shed.
Kumar Jain, BU Head of EPC, Vikram Solar

The structures should be tall enough to withstand flooding conditions and strong enough to withstand strong winds.
Bharat Bhut, Founder, Director, Goldi Solar Pvt. Ltd

PV plant designs need customisation and general price perception should factor local installation concerns to ensure decent quality across the projects lifetime.
Shilpi Dangi, DGM Engineering, Gensol Engineering Ltd Gensol

Unless, the ration provided and the ration required for the climate is same, the module won’t withstand in extreme conditions.
Shashikiran NK, Managing Director, Arushi Green Energy (India) Private Limited