INDUSTRIAL VISIT REPORT

SAGAR BHATIA C-125

TATA POWER SOLAR

A complete report based on an industrial visit organized by Xaviers Institute of
Management and Entrepreneurship for the students of PGDM to enhance there
technical as well as managerial skills and to let them having an overview on the
activities related to manufacturing process carried out by Tata Power Solar.

Company Profile
Tata Power Solar, a pioneer in the solar industry, offers a broad range of
photovoltaic solar modules that feature high efficiency and best-in-class
manufacturing edge. With an in-house production capacity of 300 & 400 MW
respectively for cells and modules, our broad range of solar energy panels and
modules are among the top-tier PV panels available to multiple customer segments
including industrial, commercial, residential as well as on-grid and off-grid solar
projects. Our facilities can process both mono and multi-crystalline wafers of
125mm and 156mm sizes.

With investments and focus on technology innovation with cutting edge

manufacturing Tata Power Solar has, shipped over 1 GW of modules worldwide,
making us one of the most respected and admired names in solar manufacturing
industry, in recognition of our quality and reliability in products, as well as project
execution both within India and worldwide.
Over the last 27 years, our modules have powered some of the biggest industry and
utility scale projects across the world including North America and Europe.

Tata Power Solar manufacturing facilities are proudly known to set and follow the
highest safety standards and equipped with the latest technology to consistently
raise the bar for solar power products around the world.

Built to perform and last, Tata Power Solar modules survive extreme wind, snow-
load and corrosive environments. Design innovations include:

Enhanced low light performance through higher shunt resistance

Long life with scrim EVA and polyester back sheet
Higher efficiency with equal absorption spectrum of the cells and
transmission spectrum of the module front glass
Proprietary manufacturing processes to minimize moisture ingress
Cells sorted by power and by current to optimize output performance

Modules manufactured by Tata Power Solar

Tata Power Solar manufactures the products according to the demand of the client
or the respective they are dealing with. Some of the standard modules
manufactured by Tata Power Solar are:-

TP Series

Robust and rugged premium PV modules, built to withstand extreme wind pressure and snow-
loads with positive power tolerance and 25 year linear power warranty

1. TP 250 Series
60 cell configuration with wattage ranging from 240 to 260W
Enhanced reliability through use of distinctive encapsulate and back sheet
Electroluminescence tested for micro- cracks
High fill factor for improved energy conversion efficiency
Unique back sheet design for high resistance to moisture ingress

2. TP 300 Series
72 cell configuration with wattage ranging from 280 to 310W
Highly reliable IP67 rated junction box
 Cells sorted by power and current to minimize mismatch losses in the field
MC4/MC4 compatible cable connectors

TS Series
The economical choice, designed for moderate environmental conditions. Solar PV Modules / Solar
PV Panels in this range

1. TS 250 Series
60 cell configuration with wattage ranging from 235 to 250W

Electroluminescence tested for micro-cracks

High fill factor for improved energy conversion efficiency

Manufacturing Process
From cell to module the following are the steps in manufacturing of solar module

Raw silicon wafers having a thickness of 18020 microns are ordered from china which
costs around 9.6cents/piece.
This silicon wafer goes under the process of etching to form textures.
Texturization is the most important process of improving efficiency of Si solar cells.
Phosphorous diffusion is done to combine p and n junctions.
The phosphorous glass used for diffusion of p and n junction is now removed.
The plate now goes for the dust cleaning process.
After the dust cleaning the sheet undergoes chemical cleaning process in which chemicals
like HF/HCL/HNO3 are used.
The chemically cleaned sheet goes under the process of crack detection through infrared
detection.
Now the sheet undergoes the process of ARC i.e Anti-Reflecting coating to minimize
reflection.
Printing is done oh the sheet to form electrodes.
Back bus bars are printed on the back aluminum side.
The sheet is then dried at a temperature of around 300-400C.
 The panels are then segregated according to their power generating capacity.
The panels made are then send for the manufacturing of module. White color copper wire
are used for soldering the panels.
A glass sheet usually made for tedlar material is taken and this sheet goes under the
process of cleaning.
After the cleaning process the glass is covered by EVA sheet.
Now the soldered panels are laid down by the automated machine on the EVA sheet.
Bus soldering is done manually by the workers.
After that the laminating program is executed in which the eva sheet is laminated to the
glass sheet at temperature around 180-200C.
The prepared sheet then goes under inspection for cracks and cuts.
After inspection it undergoes electro laminated test for detection of minute cracks.
A aluminum back sheet is taken on which the laminated sheet is fixed.
On the other hand framing process is done side by side and aluminum frames are created
in which the sheets are fixed.
The prepared modules then goes under the process of drying and cleaning.
The final is the flash test to check the wattage of the module.
RF id tag is pasted on the module for the customer so that at any point of time if the client
wants to know about the module all information can be obtained through the tag.

The above following are the steps in manufacturing of a module.

CONCLUSION
With a legacy of technology innovation and cutting edge manufacturing, Tata Power Solar is a
respected name and recognized for its efforts driven by quality and reliability both in their
products as well as project execution both within India and worldwide. Module manufacturing
lines have an in-house production capacity of 400 MW for modules and the cell manufacturing
lines with a capacity of 300MW can process both mono and multi-crystalline wafers of 125mm
and 156mm sizes.