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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP

PV SYSTEM AT CSIR-CSIO, CHANDIGARH

Central Scientific Instruments Organization (CSIO),


Chandigarh
Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
Organization (CSIR-CSIO), Chandigarh

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
Organization (CSIR-CSIO), Chandigarh

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 949.58KWp.
3 Project Location Chandigarh
a) Site Name Central Scientific Instruments
Organization (CSIR- CSIO)
b) State Chandigarh
e) District Chandigarh
f) Latitude 30.712509 N
g) Longitude 76.783503 E
h) Altitude 321 Mtr.
4 Connectivity
a) Nearest Railway Station Chandigarh Railway Station (5.3KM)
b) Nearest Airport Chandigarh Airport(15 km))

5 Roof Details
a) Total Area Available (Unshaded) 11395 Sq. M
b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 1567 MWh
annum
b) CUF 18.85%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 1567 MWh
b) Total Saving (first year) Rs. 87.75 Lakh
c) Total Saving (25 years) Rs. 2194 Cr

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
Organization (CSIR-CSIO), Chandigarh

2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 949.58
KWp DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

− Site Survey as per the standard format provided by MNRE.


− Study of the electrical load requirement and captive consumption of the establishment
at the site.
− Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
− Estimate the power generation potential depending on the site conditions.
− Preparation of preliminary Feasibility Report
− Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
− Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
− The consultant shall provide cost estimates associated with the project Detailed
Project Report of 949.58 KWp Solar Rooftop Power Plant, Central Scientific
Instruments organization, Chandigarh.

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
Organization (CSIR-CSIO), Chandigarh

o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
− The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
− The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
− power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
− Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
Central Scientific Instruments organization, Chandigarh.

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
Organization (CSIR-CSIO), Chandigarh

3. All Information as per Form B


3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at Central
Scientific Instruments organization
(CSIR-CSIO)
2. Capacity of the plant (kWp) 949.58 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. Vinod Kumar Gupta
Designation Sr.S.E
Mobile Number
9815600945
E-mail
Electrical.section@yahoo.com
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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3 Details of Proposed Power Plant


a) Proposed capacity of the SPV Power Plant (KWp) 949.58 KWp
b) Plant proposed at single site/multiple Single Site
c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 950 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
11395 SQM. So Total Proposed
Capacity of plant is 949.58 KWp.

g) Expected annual energy generation 1567 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as 4972 KVA
per electricity bill)
(ii) Applicable consumer category Commercial
(domestic/commercial/individual/ others)
(iii) Total electrical load to be met by the SPV 950 KW
power plant (kW)

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 2970 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)
5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation
axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A
(kVA) (Details of quality of output power, standards) Capacity – 50 Kw
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%
8. Number of PCU/inverters proposed to be used 19

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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9. DC Bus voltage 1000 V

10. Capacity of battery bank (Current, Voltage and AH), if Not Applicable
used, any
11. Type of battery proposed (lead acid tubular/ lithium Not Applicable
ion/ NaS/ any other)
12. Details of protections to be deployed on PV array and SPD, DC isolator, DC MCB, AC MCB,
AC output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging
points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure
16. Details of building to install the Electronics Control Existing ACDB Room
Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as control
room
(ii) If a new building is to be constructed, area, estimated
cost, and etc. to be provided and time frame to
construct the building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual
and schedule to be prepared by the EPC
contractor. Some indicative standard practice
are as follows:
• Periodic cleaning of PV modules
• Preventive maintenance such as
cable lug condition check, junction
box fuse inspection etc.
• Safety guidelines and PPE shall be
available at site

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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− Arrangements for Generation Data • Online monitoring of plant


Collection through remote monitoring performance through WMS shall be
(applicable for SPV Power Plants having installed at each site individually.
more than 5 kWp capacity) • The generation & weather data will
be recorded and stored on portal and
able to access remotely.
• Generation data, cleaning records,
spare part inventory shall be
maintained in Daily/ Monthly solar
log book.

3.4. Project Duration and Implementation Schedule [D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 227.9


2 Inverters 6 57.0
3 Module Mounting Structures 4 38.0
4 Electrical wires 4 38.0
5 Net Metering and other approval 2 19.0
6 BOS 4 38.0
7 Installation & Commissioning 4 38.0
8 O&M Cost for 5 Years 5 47.5
Total Cost 53 503.3

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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5. System Description and Specification of the Components


Any solar PV power project consists of following major components

• Solar PV modules
• String Inverters
• Transformers
• Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

PV Module type : Multi crystalline


Make : CEL
Model : PM320

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm
Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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Nominal AC Output Power, Pac : 50 kW


Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.

Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to
inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
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Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
Organization (CSIR-CSIO), Chandigarh

6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
Organization (CSIR-CSIO), Chandigarh

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 1567
MWh/year, with Specific Energy Yield of 1649 kWh/KWp/year and performance ratio of 80.45 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 98.8 42.3 12.2 136.6 130 115.2 113.6 0.875
February 119 45.2 15.81 152.9 145.8 125.9 124.1 0.854
March 164.6 64.7 21.35 190.4 180.8 151.8 149.4 0.826
April 182.2 78.5 27.36 190.8 181 147.5 145 0.8
May 200.4 97.3 31.64 194.6 184.3 148.1 135.1 0.73
June 181.9 102.9 31.35 171.3 161.9 131.5 129.4 0.795
July 162.1 99.9 30.7 153.7 145.1 118.9 117.1 0.801
August 162.9 92.5 29.7 162.7 154.1 126.6 124.6 0.806
September 158.9 68.7 27.7 176.1 167.1 137.1 134.9 0.806
October 152.8 49.4 24.45 191.4 182.6 150.8 137.4 0.755
November 121.8 29.5 18.38 174.2 166.6 141.5 134.3 0.811
December 103.4 31.4 13.97 154.7 147.7 129.1 122.3 0.832
Year 1808.9 802.4 23.75 2049.4 1947.1 1624 1567 0.805

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Detailed Project Report of Solar Rooftop PV System at Central Scientific Instruments
Organization (CSIR-CSIO), Chandigarh

Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-IMTECH, CHANDIGARH

Institute of Microbial Technology (IMTECH), Chandigarh


Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
(CSIR-IMTECH), Chandigarh

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
(CSIR-IMTECH), Chandigarh

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 399.95KWp.
3 Project Location Chandigarh
a) Site Name Institute of Microbial Techology (CSIR-
IMTECH)
b) State Chandigarh
e) District Chandigarh
f) Latitude 30.74766 N
g) Longitude 77.73341 E
h) Altitude 321 Mtr.
4 Connectivity
a) Nearest Railway Station Chandigrah Railway Station (14KM)

b) Nearest Airport Chandigrah Airport(15 km)

5 Roof Details
a) Total Area Available (Unshaded) 4799.45 Sq. M

b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 706.3 MWh
annum
b) CUF 20.16%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 706.3 MWh
b) Total Saving (first year) Rs. 39.55 Lakh
c) Total Saving (25 years) Rs. 9.89 Cr

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
(CSIR-IMTECH), Chandigarh

2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 399.95
KWp DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 399.5 KWp Solar Rooftop Power Plant, Institute of Microbial
Techology, Chandigarh .

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
(CSIR-IMTECH), Chandigarh

o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
Institute of Microbial Techology, Chandigarh .

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
(CSIR-IMTECH), Chandigarh

3. All Information as per Form B


3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at Institute of
Microbial Techology (CSIR-IMTECH)
2. Capacity of the plant (kWp) 399.95 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. H.B.K Bhatti
Designation Asst. Executive Engineer
Mobile Number
9814905289
E-mail
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail
3 Details of Proposed Power Plant

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
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a) Proposed capacity of the SPV Power Plant (KWp) 399.95 KWp


b) Plant proposed at single site/multiple Single Site
c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 400 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
4799.45 SQM. So Total Proposed
Capacity of plant is 399.95 KWp.

g) Expected annual energy generation 159.8 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as 5592 KW
per electricity bill)
(ii) Applicable consumer category Commercial
(domestic/commercial/individual/ others)
(iii) Total electrical load to be met by the SPV 400 KW
power plant (kW)

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 1254 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)
5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation
axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A
(kVA) (Details of quality of output power, standards) Capacity – 50 Kw
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%
8. Number of PCU/inverters proposed to be used 8

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
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9. DC Bus voltage 1000 V

10. Capacity of battery bank (Current, Voltage and AH), if Not Applicable
used, any
11. Type of battery proposed (lead acid tubular/ lithium Not Applicable
ion/ NaS/ any other)
12. Details of protections to be deployed on PV array and SPD, DC isolator, DC MCB, AC MCB,
AC output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging
points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure
16. Details of building to install the Electronics Control Existing ACDB Room
Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as control
room
(ii) If a new building is to be constructed, area, estimated
cost, and etc. to be provided and time frame to
construct the building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual
and schedule to be prepared by the EPC
contractor. Some indicative standard practice
are as follows:
 Periodic cleaning of PV modules
 Preventive maintenance such as
cable lug condition check, junction
box fuse inspection etc.
 Safety guidelines and PPE shall be
available at site

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
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− Arrangements for Generation Data  Online monitoring of plant


Collection through remote monitoring performance through WMS shall be
(applicable for SPV Power Plants having installed at each site individually.
more than 5 kWp capacity)  The generation & weather data will
be recorded and stored on portal and
able to access remotely.
 Generation data, cleaning records,
spare part inventory shall be
maintained in Daily/ Monthly solar
log book.

3.4. Project Duration and Implementation Schedule [D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
(CSIR-IMTECH), Chandigarh

1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
(CSIR-IMTECH), Chandigarh

4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
(CSIR-IMTECH), Chandigarh

3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 96.0


2 Inverters 6 24.0
3 Module Mounting Structures 4 16.0
4 Electrical wires 4 16.0
5 Net Metering and other approval 2 8.0
6 BOS 4 16.0
7 Installation & Commissioning 4 16.0
8 O&M Cost for 5 Years 5 20.0
Total Cost 53 212.0

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
(CSIR-IMTECH), Chandigarh

4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
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A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
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5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

PV Module type : Multi crystalline


Make : CEL
Model : PM320

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
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Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm
Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
(CSIR-IMTECH), Chandigarh

Nominal AC Output Power, Pac : 50 kW


Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.

Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

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LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to
inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
(CSIR-IMTECH), Chandigarh

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
(CSIR-IMTECH), Chandigarh

6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
(CSIR-IMTECH), Chandigarh

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 706.3
MWh/year, with Specific Energy Yield of 1760 kWh/KWp/year and performance ratio of 80.32%.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 117.2 27.3 12.29 172.4 165 61.12 60.25 0.871
February 122.3 42.5 15.78 158.7 151.4 55.26 54.47 0.855
March 172.5 58.4 21.25 201.8 192 67.92 66.93 0.827
April 191.9 71.8 27.22 201.5 191 65.66 58.44 0.723
May 215.6 87.3 31.46 208.9 197.8 66.94 61.24 0.731
June 187.6 101 31.08 176.8 167.2 57.32 56.48 0.796
July 158 97 30.49 150 141.6 49.09 48.38 0.804
August 161.7 94.1 29.38 161.6 152.7 53.14 52.38 0.808
September 160.7 68.7 27.4 176.7 167.6 58.14 57.29 0.808
October 167.3 31.4 24.28 213.5 204.3 70.77 69.69 0.813
November 131.8 21.2 18.29 192.1 183.7 65.65 59.4 0.771
December 114.5 21.1 13.97 177.5 169.9 62.26 61.37 0.862
Year 1901.2 722 23.61 2191.5 2084.3 733.27 706.33 0.803

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Detailed Project Report of Solar Rooftop PV System at Institute of Microbial Technology
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Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-IHBT, PALAMPUR

Institute of Himalayan Bioresource Technology (IHBT),


Palampur, Himachal Pradesh.
Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 2
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 256.4 KWp.
3 Project Location Palampur, Himachal Pradesh
a) Site Name Institute of Himalayan Bioresource
Technology (CSIR- IHBT)
b) State Himachal Pradesh
e) District Kangra
f) Latitude 32.1042 N
g) Longitude 76.5559 E
h) Altitude 1219 Mtr.
4 Connectivity
a) Nearest Railway Station Palampur Railway Station (8KM)
b) Nearest Airport Kangra Airport (45 km)

5 Roof Details
a) Total Area Available (Unshaded) 3077 Sq. M
b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 418.2 MWh
annum
b) CUF 18.67%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 418.2 MWh
b) Total Saving (first year) Rs. 19.65 Lakh
c) Total Saving (25 years) Rs. 4.91 Cr

2. Introduction

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 256.4
KWp DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

− Site Survey as per the standard format provided by MNRE.


− Study of the electrical load requirement and captive consumption of the establishment
at the site.
− Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
− Estimate the power generation potential depending on the site conditions.
− Preparation of preliminary Feasibility Report
− Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
− Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
− The consultant shall provide cost estimates associated with the project Detailed
Project Report of 256.4 KWp Solar Rooftop Power Plant, Institute of Himalayan
Bioresource Technology, Palampur, Himachal Pradesh.

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
− The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
− The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
− power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
− Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
Institute of Himalayan Bioresource Technology, Palampur, Himachal Pradesh.

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

3. All Information as per Form B


3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at Institute of
Himalayan Bioresource Technology,
Palampur, Himachal Pradesh. (CSIR-
IMBT)
2. Capacity of the plant (kWp) 256.4 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. Mukesh Gautam
Designation Asst. Executive Engineer
Mobile Number
9418065274
E-mail
mukesh@ihbt.res.in
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
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Full address, phone, mobile and e-mail


3 Details of Proposed Power Plant
a) Proposed capacity of the SPV Power Plant (KWp) 256.4 KWp
b) Plant proposed at single site/multiple Single Site
c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 260 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
3077 SQM. So Total Proposed
Capacity of plant is 256.4 KWp.

g) Expected annual energy generation 418.2 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as 444.5 & 162.30 KVA
per electricity bill)
(ii) Applicable consumer category Commercial
(domestic/commercial/individual/ others)
(iii) Total electrical load to be met by the SPV 260 KW
power plant (kW)

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 798 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)
5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation
axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A & RPI M 10 A
(kVA) (Details of quality of output power, standards) Capacity – 50 Kw & 10 KW
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

8. Number of PCU/inverters proposed to be used 6 (50 KW X5 & 10 KW X1)

9. DC Bus voltage 1000 V

10. Capacity of battery bank (Current, Voltage and AH), if Not Applicable
used, any
11. Type of battery proposed (lead acid tubular/ lithium Not Applicable
ion/ NaS/ any other)
12. Details of protections to be deployed on PV array and SPD, DC isolator, DC MCB, AC MCB,
AC output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging
points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure
16. Details of building to install the Electronics Control Existing ACDB Room
Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as control
room
(ii) If a new building is to be constructed, area, estimated
cost, and etc. to be provided and time frame to
construct the building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual
and schedule to be prepared by the EPC
contractor. Some indicative standard practice
are as follows:
• Periodic cleaning of PV modules
• Preventive maintenance such as
cable lug condition check, junction
box fuse inspection etc.
• Safety guidelines and PPE shall be
available at site

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

− Arrangements for Generation Data • Online monitoring of plant


Collection through remote monitoring performance through WMS shall be
(applicable for SPV Power Plants having installed at each site individually.
more than 5 kWp capacity) • The generation & weather data will
be recorded and stored on portal and
able to access remotely.
• Generation data, cleaning records,
spare part inventory shall be
maintained in Daily/ Monthly solar
log book.

3.4. Project Duration and Implementation Schedule [D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 61.5


2 Inverters 6 15.4
3 Module Mounting Structures 4 10.3
4 Electrical wires 4 10.3
5 Net Metering and other approval 2 5.1
6 BOS 4 10.3
7 Installation & Commissioning 4 10.3
8 O&M Cost for 5 Years 5 12.8
Total Cost 53 135.9

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

5. System Description and Specification of the Components


Any solar PV power project consists of following major components

• Solar PV modules
• String Inverters
• Transformers
• Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

PV Module type : Multi crystalline


Make : CEL
Model : PM320

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm
Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

Nominal AC Output Power, Pac : 50 kW


Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.

Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to
inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 418.2
MWh/year, with Specific Energy Yield of 1638 kWh/KWp/year and performance ratio of 80.64 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 97.5 38.9 11.18 138.6 132 31.54 31.09 0.879
February 102.6 53.4 15.07 127.6 121.3 28.47 28.07 0.861
March 145.7 73 20.64 166.8 158.3 36.01 35.49 0.833
April 163.4 86.2 26.38 170.4 161.4 35.7 35.18 0.809
May 200.8 95.5 31.98 196.3 185.9 39.97 39.36 0.785
June 193.5 99.8 31.65 183.5 173.7 37.71 37.16 0.793
July 166.7 102.4 30.62 158.7 149.7 33 30.31 0.748
August 163.2 95.3 30.12 163.9 155 34.16 30.2 0.722
September 167.7 68.3 28.02 187.5 178.1 39.16 36.36 0.759
October 160 33.6 24.96 206.4 197.3 43.39 42.74 0.811
November 121.3 24.3 18.32 178.2 170.4 38.86 38.31 0.842
December 99.4 28.4 13.11 152.6 145.9 34.37 33.88 0.869
Year 1781.8 798.8 23.55 2030.6 1928.8 432.33 418.15 0.806

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Detailed Project Report of Solar Rooftop PV System at Institute of Himalayan Bioresource
Technology (CSIR-IHBT), Palampur

Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-CSMCRI, BHAVNAGAR

Central Salt Marine Chemicals Research institute,


Bhavnagar, Gujrat.
Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 8
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

1|Page
Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 216 KWp.
3 Project Location Bhavnagar, Gujrat
a) Site Name Central Salt Marine Chemicals Research
institute (CSIR-CSMCRI)
b) State Gujrat
e) District Bhavnagar
f) Latitude 21.7590N
g) Longitude 72.1445E
h) Altitude 24 Mtr. above MSL
4 Connectivity
a) Nearest Railway Station Bhavnagar Terminus 5 KM

b) Nearest Airport Bhavnagar Airport 5 KM

5 Roof Details
a) Total Area Available (Unshaded) 2593.09 Sq. M

b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 382.9 MWh
annum
b) CUF 20.23 %
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 382.9 MWh
b) Total Saving (first year) Rs. 22.40 Lakh
c) Total Saving (25 years) Rs. 5.60 Cr

2|Page
Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 216 KWp
DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 216 KWp Solar Rooftop Power Plant, Central Salt Marine Chemicals
Research institute, Bhavnagar.

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
Central Salt Marine Chemicals Research institute, Bhavnagar.

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

3. All Information as per Form B


3.1. Project Details [A]

S. Description Remark
No
1. Title of the Project SPV Grid tied Project at Central Salt
Marine Chemicals Research
Institute (CSIR-CSMRI)
2. Capacity of the plant (kWp) 216 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. M.P Makwana
Designation
Mobile Number Executive Engineer (Civil)
E-mail 9712524421
mpmakwana@csmcri.res.in
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee
at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S Description Remarks
No.
1 Is the plant located at the address mentioned in [A] Same as [A]4
4 above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

2 Is the beneficiary same as [B] 1 If No, Details of Same as [B]1


Project Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail
3 Details of Proposed Power Plant
a) Proposed capacity of the SPV Power Plant 216 KWp
(KWp) Single Site
b) Plant proposed at single site/multiple Single Point
c) Interconnection with the electricity network
at single point or multiple point Yes
d) Availability of shadow free south facing
rooftop/ land area for the power plant 220 KW
e) Total loads to be energized by SPV Power
Plant(KW) As per industry practice the area
f) Calculations and justification for the proposed required per KWp is around 12
capacity (Please elaborate) sqm. The total available area at
the roof to install the plant is
around 2593.09 SQM. So Total
Proposed Capacity of plant is
216 KWp.

g) Expected annual energy generation 382.9 MWh/year


h) Space for housing the plant control systems NA
and battery bank (if any)

4 Details of electrical load where the plant is to be


installed
(i) Total connected electrical load in KW/KVA 750 KVA
(as per electricity bill)
(ii) Applicable consumer category Commercial
(domestic/commercial/individual/ others)
(iii) Total electrical load to be met by the SPV 220 KW
power plant (kW)

5 Technology Description & System


Design/Specification
1. Sketch/Line diagram of the complete SPV System Attached
with details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. 680 modules
& kWp)

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

4. Solar cell technology and Module efficiency Poly crystalline


proposed to be used (mono-crystalline/ poly- Efficiency – 16.5 %
crystalline/ thin film/ any other)
5. Details of Tracking of PV Array, if proposed Fixed tilt installation
(single axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A & Delta RPI
(kVA) (Details of quality of output power, M20 A
standards) Capacity – 50 Kw & 20 Kw
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%
8. Number of PCU/inverters proposed to be used 5 (50 KW X 4 & 20 KW X1)
9. DC Bus voltage 1000 V
10. Capacity of battery bank (Current, Voltage and Not Applicable
AH), if used, any
11. Type of battery proposed (lead acid tubular/ Not Applicable
lithium ion/ NaS/ any other)
12. Details of protections to be deployed on PV array SPD, DC isolator, DC MCB, AC
and AC output side MCB, Fuses, Overcurrent relays,
Reverse power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and
regular data logging of the SPV
system.
14. Schematic diagram of the system including DDE
protecting interlocking devices, monitoring and
data logging points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure
16. Details of building to install the Electronics Existing ACDB Room
Control Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as
control room
(ii) If a new building is to be constructed, area,
estimated cost, and etc. to be provided and time
frame to construct the building

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment
Arrangements is tabulated in annexure I & II. Detail
manual and schedule to be prepared by
the EPC contractor. Some indicative
standard practice are as follows:
 Periodic cleaning of PV modules
 Preventive maintenance such as
cable lug condition check, junction
box fuse inspection etc.
 Safety guidelines and PPE shall be
available at site

− Arrangements for Generation Data  Online monitoring of plant


Collection through remote monitoring performance through WMS shall
(applicable for SPV Power Plants having be installed at each site
more than 5 kWp capacity) individually.
 The generation & weather data
will be recorded and stored on
portal and able to access
remotely.
 Generation data, cleaning records,
spare part inventory shall be
maintained in Daily/ Monthly
solar log book.

3.4. Project Duration and Implementation Schedule [D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 51.8


2 Inverters 6 13.0
3 Module Mounting Structures 4 8.6
4 Electrical wires 4 8.6
5 Net Metering and other approval 2 4.3
6 BOS 4 8.6
7 Installation & Commissioning 4 8.6
8 O&M Cost for 5 Years 5 10.8
Total Cost 53 114.5

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.
A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

PV Module type : Multi crystalline


Make : CEL
Model : PM320

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm
Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

Nominal AC Output Power, Pac : 50 kW


Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.

Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to
inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 508.6
MWh/year, with Specific Energy Yield of 1605 kWh/KWp/year and performance ratio of 80.04 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 158 25.78 21.64 205.6 196.5 37.48 36.76 0.822
February 164.6 32.14 23.57 197.5 188.8 35.47 34.74 0.809
March 200 51.95 27.58 218.7 208.5 38.49 37.67 0.792
April 209.1 69.61 29.83 210.9 200.3 36.88 36.11 0.787
May 220.9 81.76 31.02 208.5 197.5 36.55 35.82 0.79
June 181.4 99.59 29.87 168.3 158.9 30.01 29.46 0.804
July 139.4 93.99 28.57 131.1 123.4 23.59 23.17 0.812
August 132.1 83.48 27.64 128.8 121.4 23.21 22.8 0.813
September 164.6 75.5 28.09 172.9 163.8 30.93 24.46 0.65
October 181.4 50.92 28.23 210 200 37.1 33.42 0.731
November 154 35.15 25.47 193.6 185.1 34.73 34.03 0.808
December 146.3 28.14 22.9 193.1 184.8 35.1 34.43 0.82
Year 2051.9 728 27.05 2239 2129 399.53 382.87 0.786

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Detailed Project Report of Solar Rooftop PV System at Central Salt Marine Chemicals
Research institute (CSIR-CSMCRI), Bhavnagar, Gujrat

Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-NIO, GOA

National Institute of Oceanography (NIO), GOA


Detailed Project Report of Solar Rooftop PV System at National Institute of Oceanography
(CSIR-NIO), GOA

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at National Institute of Oceanography
(CSIR-NIO), GOA

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 1064 KWp.
3 Project Location Dona Paula , Goa
a) Site Name National Institute of Oceanography (CSIR-
NIO)
b) State Goa
e) District Dona Paula , Goa
f) Latitude 15.45N
g) Longitude 73.80E
h) Altitude 1022 Mtr. above MSL
4 Connectivity
a) Nearest Railway Station Karmali Railway Station

b) Nearest Airport Dabolim Airport (approx. 90 KMs)

5 Roof Details
a) Total Area Available (Unshaded) 12772 Sq. M

b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 1675 MWh
annum
b) CUF 18.31%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 1575 MWh
b) Total Saving (first year) Rs. 92.15 Lakh
c) Total Saving (25 years) Rs. 23.04 Cr

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Detailed Project Report of Solar Rooftop PV System at National Institute of Oceanography
(CSIR-NIO), GOA

2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 1064
KWp DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 1064 KWp Solar Rooftop Power Plant, National Institute of
Oceanography (CSIR-NIO), GOA.

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o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
National Institute of Oceanography (CSIR-NIO), GOA.

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3. All Information as per Form B

3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at National
Institute of Oceanography
2. Capacity of the plant (kWp) 1064 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Shri Rajendra Phutankar
Designation Executive Engineer
Mobile Number 9423881881
E-mail
phutankar@nio.org
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail

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3 Details of Proposed Power Plant


a) Proposed capacity of the SPV Power Plant (KWp) 1064 KWp
b) Plant proposed at single site/multiple Single Site
c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 1060 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
12772 SQM. So Total Proposed
Capacity of plant is 1064 KWp.

g) Expected annual energy generation 1675 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as 990 KVA
per electricity bill)
(ii) Applicable consumer category Commercial
(domestic/commercial/individual/ others)
(iii) Total electrical load to be met by the SPV 1060 KW
power plant (kW)

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 3325 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)
5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation
axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A & Delta RPI M60 A
(kVA) (Details of quality of output power, standards) Capacity – 50 Kw & 60 kw
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%
8. Number of PCU/inverters proposed to be used 21( 50 kw X 20 & 60 Kw X 1)
9. DC Bus voltage 1000 V

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10. Capacity of battery bank (Current, Voltage and AH), if Not Applicable
used, any
11. Type of battery proposed (lead acid tubular/ lithium Not Applicable
ion/ NaS/ any other)
12. Details of protections to be deployed on PV array and SPD, DC isolator, DC MCB, AC MCB,
AC output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging
points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure
16. Details of building to install the Electronics Control Existing ACDB Room
Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as control
room
(ii) If a new building is to be constructed, area, estimated
cost, and etc. to be provided and time frame to
construct the building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual
and schedule to be prepared by the EPC
contractor. Some indicative standard practice
are as follows:
 Periodic cleaning of PV modules
 Preventive maintenance such as
cable lug condition check, junction
box fuse inspection etc.
 Safety guidelines and PPE shall be
available at site

− Arrangements for Generation Data  Online monitoring of plant


Collection through remote monitoring performance through WMS shall be
(applicable for SPV Power Plants having installed at each site individually.
more than 5 kWp capacity)  The generation & weather data will
be recorded and stored on portal and
able to access remotely.

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 Generation data, cleaning records,


spare part inventory shall be
maintained in Daily/ Monthly solar
log book.

3.4. Project Duration and Implementation Schedule [D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

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1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

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4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 255.4


2 Inverters 6 63.8
3 Module Mounting Structures 4 42.6
4 Electrical wires 4 42.6
5 Net Metering and other approval 2 21.3
6 BOS 4 42.6
7 Installation & Commissioning 4 42.6
8 O&M Cost for 5 Years 5 53.2
Total Cost 53 563.9

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4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.
A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

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Figure 1 Typical Solar PV System diagram

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5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

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PV Module type : Multi crystalline


Make : CEL
Model : PM320

Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm

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Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V
Nominal AC Output Power, Pac : 50 kW
Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.
Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

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LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to
inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

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Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 1675
MWh/year, with Specific Energy Yield of 1575 kWh/KWp/year and performance ratio of 79.53 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 158.8 52.29 25.82 185.3 176.4 162.9 160.5 0.814
February 164 53.82 26.3 182.6 173.8 159.6 157.2 0.809
March 193.3 72.02 27.82 203 192.6 176.4 173.7 0.804
April 192.5 77.75 29.12 190.6 180.6 165 144.9 0.714
May 195.6 82.85 29.86 185.5 175.6 160.6 158.2 0.801
June 126.3 81.62 27.34 118.9 111.8 105 103.5 0.818
July 123.8 83.1 27.05 117.1 110.1 103.5 102 0.818
August 138.4 91.04 26.68 134.5 126.5 119.2 111.5 0.779
September 144.1 80.42 26.52 146.1 137.7 128.7 126.8 0.816
October 155.7 72.91 27.71 166.9 158 145.8 135.6 0.763
November 150 56.49 27.24 171.7 163.1 150.2 148 0.81
December 150.2 53.16 26.31 177.8 169 156 153.7 0.812
Year 1892.8 857.47 27.32 1980.1 1875.2 1732.9 1675.5 0.795

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Detailed Project Report of Solar Rooftop PV System at National Institute of Oceanography
(CSIR-NIO), GOA

Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-NIIST,KERALA

National Institute for Interdisciplinary Science and


Technology (NSSIT), Thiruvananthapuram, Kerala
Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 194 KWp.
3 Project Location Kerala
a) Site Name CSIR –National Institute for
Interdisciplinary Science and Technology
(NIIST)
b) State Kerala
e) District Thiruvananthapuram
f) Latitude 8°28’11” N
g) Longitude 76°59’28” E
h) Altitude 457.2 Mtr. above MSL
4 Connectivity
a) Nearest Railway Station Trivandrum Central Railway Station

b) Nearest Airport Trivandrum International Airport

5 Roof Details
a) Total Area Available (Unshaded) 2330 Sq.M

b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 315.6MWh
annum
b) CUF 18.57%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 315.6 MWh
b) Total Saving (first year) Rs. 20.04 Lakh
c) Total Saving (25 years) Rs. 5.06 Cr

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 194 KWp
DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 194 KWp Solar Rooftop Power Plant, National Institute for
Interdisciplinary Science and Technology (NIIST), Kerala.

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
National Institute for Interdisciplinary Science and Technology (NIIST), Kerala.

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

3. All Information as per Form B


3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project National
Institute for Interdisciplinary Science
and Technology (NIIST)
2. Capacity of the plant (kWp) 194 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. Chandra Sekar Neelam
Designation Asst. Executive Engineer
Mobile Number 9495094755
E-mail Chandrashekar9777@gmail.com
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail
3 Details of Proposed Power Plant
a) Proposed capacity of the SPV Power Plant (KWp) 194 KWp

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

b) Plant proposed at single site/multiple Single Site


c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 200 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
2330 SQM. So Total Proposed
Capacity of plant is 194 KWp.

g) Expected annual energy generation 315.6 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as
per electricity bill) 1200 KVA
(ii) Applicable consumer category
(domestic/commercial/individual/ others) Commercial
(iii) Total electrical load to be met by the SPV
power plant (kW) 200 KW

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 612 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)
5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation
axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A
(kVA) (Details of quality of output power, standards) Capacity – 50 KW
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

8. Number of PCU/inverters proposed to be used 4

9. DC Bus voltage 1000 V


10. Capacity of battery bank (Current, Voltage and AH), if Not Applicable
used, any
11. Type of battery proposed (lead acid tubular/ lithium Not Applicable
ion/ NaS/ any other)
12. Details of protections to be deployed on PV array and SPD, DC isolator, DC MCB, AC MCB,
AC output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging
points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure
16. Details of building to install the Electronics Control Existing ACDB Room
Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as control
room
(ii) If a new building is to be constructed, area, estimated
cost, and etc. to be provided and time frame to
construct the building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual
and schedule to be prepared by the EPC
contractor. Some indicative standard practice
are as follows:
 Periodic cleaning of PV modules
 Preventive maintenance such as
cable lug condition check, junction
box fuse inspection etc.
 Safety guidelines and PPE shall be
available at site

− Arrangements for Generation Data  Online monitoring of plant


Collection through remote monitoring performance through WMS shall be
(applicable for SPV Power Plants having installed at each site individually.
more than 5 kWp capacity)

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
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 The generation & weather data will


be recorded and stored on portal and
able to access remotely.
 Generation data, cleaning records,
spare part inventory shall be
maintained in Daily/ Monthly solar
log book.

3.4. Project Duration and Implementation Schedule[D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 46.6


2 Inverters 6 11.6
3 Module Mounting Structures 4 7.8
4 Electrical wires 4 7.8
5 Net Metering and other approval 2 3.9
6 BOS 4 7.8
7 Installation & Commissioning 4 7.8
8 O&M Cost for 5 Years 5 9.7
Total Cost 53 102.8

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.
A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

PV Module type : Multi crystalline


Make : CEL
Model : PM320

Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
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Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V
Nominal AC Output Power, Pac : 50 kW
Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.
Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to
inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 315.6
MWh/year, with Specific Energy Yield of 1612 kWh/KWp/year and performance ratio of 79.82 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 172.6 60.57 27.18 188.3 180.3 30.46 29.9 0.811
February 170.3 67.1 27.78 180.5 172.8 29.14 28.59 0.809
March 199.8 73.25 28.73 203.5 194.7 32.58 31.96 0.802
April 179.6 79.29 28.29 176.6 168.5 28.46 25.87 0.748
May 167.9 81.02 28.56 160.8 153.2 26.03 21.44 0.681
June 134.4 85.56 26.69 128 121.4 21.05 20.7 0.826
July 156.9 87.24 26.73 149.4 142 24.5 24.08 0.823
August 168.1 88.45 26.75 163.6 155.9 26.75 26.28 0.82
September 169.2 74.3 26.58 169.9 162.3 27.6 27.1 0.814
October 165.3 76.96 26.86 171.4 163.8 27.89 27.39 0.816
November 142.4 69.71 26.46 151.8 145.1 24.78 24.33 0.819
December 159.8 64.42 27.1 175.2 167.6 28.5 27.99 0.816
Year 1986.1 907.87 27.31 2019 1927.6 327.74 315.63 0.798

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Detailed Project Report of Solar Rooftop PV System at CSIR– National Institute for
Interdisciplinary Science and Technology (NIIST)

Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-4PI, BENGALURU

Fourth Paradigm Institute (CSIR-4PI), Bengaluru,


Karnataka
Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 165 KWp.
3 Project Location Bengaluru , Karnataka
a) Site Name CSIR Fourth Paradigm Institute (CSIR-4PI)

b) State Karnataka
e) District Bengaluru
f) Latitude 12°56’39” N
g) Longitude 77°39’56” E
h) Altitude 920 Mtr.
4 Connectivity
a) Nearest Railway Station KSR-Railway Station, Bengaluru.

b) Nearest Airport Kempegowda International Airport,


5 Roof Details
a) Total Area Available (Unshaded) 1990 Sq. M

b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 278.8 MWh
annum
b) CUF 19.29%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 278.8 MWh
b) Total Saving (first year) Rs. 33.45Lakh
c) Total Saving (25 years) Rs. 8.36 Cr

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 165 KWp
DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 165 KWp Solar Rooftop Power Plant, Fourth Paradigm Institute, Belur
Campus, Bengaluru.

o Basis of cost estimates

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
Fourth Paradigm Institute, Belur Campus, Bengaluru

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

3. All Information as per Form B

3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at Fourth
Paradigm Institute (CSIR-4PI)
2. Capacity of the plant (kWp) 165 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. R.Ravindran
Designation Principle Scientist & Head
Mobile Number 9902540256
E-mail
ravindran@nal.res.in
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail
3 Details of Proposed Power Plant

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

a) Proposed capacity of the SPV Power Plant (KWp) 165 KWp


b) Plant proposed at single site/multiple Single Site
c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 160 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
1990 SQM. So Total Proposed
Capacity of plant is 165 KWp.

g) Expected annual energy generation 278.8 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as
per electricity bill) 7000 KVA
(ii) Applicable consumer category
(domestic/commercial/individual/ others) Commercial
(iii) Total electrical load to be met by the SPV
power plant (kW) 160 KW

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 513 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)
5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation
axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A & RPI M10 A
(kVA) (Details of quality of output power, standards) Capacity – 50 Kw & 10 KW
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%
8. Number of PCU/inverters proposed to be used 4 (50 KW X 3 & 10 KW X 1)

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

9. DC Bus voltage 1000 V

10. Capacity of battery bank (Current, Voltage and AH), if Not Applicable
used, any
11. Type of battery proposed (lead acid tubular/ lithium Not Applicable
ion/ NaS/ any other)
12. Details of protections to be deployed on PV array and SPD, DC isolator, DC MCB, AC MCB,
AC output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging
points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure
16. Details of building to install the Electronics Control Existing ACDB Room
Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as control
room
(ii) If a new building is to be constructed, area, estimated
cost, and etc. to be provided and time frame to
construct the building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual
and schedule to be prepared by the EPC
contractor. Some indicative standard practice
are as follows:
 Periodic cleaning of PV modules
 Preventive maintenance such as
cable lug condition check, junction
box fuse inspection etc.
 Safety guidelines and PPE shall be
available at site

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

− Arrangements for Generation Data  Online monitoring of plant


Collection through remote monitoring performance through WMS shall be
(applicable for SPV Power Plants having installed at each site individually.
more than 5 kWp capacity)  The generation & weather data will
be recorded and stored on portal and
able to access remotely.
 Generation data, cleaning records,
spare part inventory shall be
maintained in Daily/ Monthly solar
log book.

3.4. Project Duration and Implementation Schedule [D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

8|Page
Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 39.6


2 Inverters 6 9.9
3 Module Mounting Structures 4 6.6
4 Electrical wires 4 6.6
5 Net Metering and other approval 2 3.3
6 BOS 4 6.6
7 Installation & Commissioning 4 6.6
8 O&M Cost for 5 Years 5 8.3
Total Cost 53 87.5

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

PV Module type : Multi crystalline


Make : CEL
Model : PM320

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm
Depth : 278 mm
Weight : 74 kg

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

Maximum Input DC Voltage : 1000 V


MPP Voltage range : 520 V - 800 V
Nominal AC Output Power, Pac : 50 kW
Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.

Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

LT Cables

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to
inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
(CSIR-4PI), Bengaluru, Karnataka

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 278.8
MWh/year, with Specific Energy Yield of 1698 kWh/KWp/year and performance ratio of 79.53 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 199.5 26.4 25.39 234.9 224.2 31.51 31 0.804
February 192.4 31.89 26.47 214.5 204.7 28.56 28.1 0.798
March 211.1 56.51 28.24 219.9 208.9 29.08 28.62 0.793
April 201.5 75.22 29.5 197.6 187.2 26.14 24.42 0.753
May 190.6 80.16 30.42 178 167.9 23.54 23.19 0.793
June 136.5 83.52 28.69 127 119.3 17.11 16.86 0.809
July 135 84.65 28.58 126.9 119.3 17.12 16.56 0.794
August 138.4 82.03 27.92 133.7 125.8 18.02 17.76 0.809
September 134.7 66.15 27.51 135.6 128.1 18.21 17.94 0.806
October 163.4 75.34 27.09 174.4 165.4 23.56 23.21 0.811
November 153.4 55.86 25.86 173 164.5 23.48 21.83 0.769
December 184.6 28.93 25.23 219.6 210 29.72 29.26 0.812
Year 2041.1 746.66 27.58 2135.1 2025.4 286.06 278.75 0.795

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Detailed Project Report of Solar Rooftop PV System at Fourth Paradigm Institute
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Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-NAL (BELUR), BENGALURU

National Aerospace Laboratories (NAL), Bengaluru,


Karnataka
Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 84 KWp.
3 Project Location Bengaluru , Karnataka
a) Site Name CSIR-National Aerospace Laboratories,
Belur Campus (CSIR-NAL)
b) State Karnataka
e) District Bengaluru
f) Latitude 12°56’46” N
g) Longitude 77°40’01” E
h) Altitude 920 Mtr.
4 Connectivity
a) Nearest Railway Station KSR-Railway Station, Bengaluru

b) Nearest Airport Kempegowda International Airport


5 Roof Details
a) Total Area Available (Unshaded) 1269 Sq. M

b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 142.5 MWh
annum
b) CUF 19.37%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 142.5 MWh
b) Total Saving (first year) Rs. 17.10 Lakh
c) Total Saving (25 years) Rs. 4.28 Cr

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 84 KWp
DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 84 KWp Solar Rooftop Power Plant, National Aerospace Laboratories,
Belur Campus, Bengaluru.

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
National Aerospace Laboratories, Belur Campus, Bengalure.

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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3. All Information as per Form B


3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at National
Aerospace Laboratories, Belur Campus
(CSIR-NAL)
2. Capacity of the plant (kWp) 84 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. R. Ravindran
Designation Principle Scientist & Head
Mobile Number 9902540256
E-mail
ravindran@nal.res.in
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail

3 Details of Proposed Power Plant

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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a) Proposed capacity of the SPV Power Plant (KWp) 84 KWp


b) Plant proposed at single site/multiple Single Site
c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 80 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
1010 SQM. So Total Proposed
Capacity of plant is 84 KWp.

g) Expected annual energy generation 142.5 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as
per electricity bill) 700 KVA
(ii) Applicable consumer category
(domestic/commercial/individual/ others) Commercial
(iii) Total electrical load to be met by the SPV
power plant (kW) 100 KW

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 266 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)
5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation
axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A & RPI M30 A
(kVA) (Details of quality of output power, standards) Capacity – 50 kW & 30 KW
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%
8. Number of PCU/inverters proposed to be used 2

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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9. DC Bus voltage 1000 V


10. Capacity of battery bank (Current, Voltage and AH), if Not Applicable
used, any
11. Type of battery proposed (lead acid tubular/ lithium Not Applicable
ion/ NaS/ any other)
12. Details of protections to be deployed on PV array and SPD, DC isolator, DC MCB, AC MCB,
AC output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging
points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure
16. Details of building to install the Electronics Control Existing ACDB Room
Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as control
room
(ii) If a new building is to be constructed, area, estimated
cost, and etc. to be provided and time frame to
construct the building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual
and schedule to be prepared by the EPC
contractor. Some indicative standard practice
are as follows:
 Periodic cleaning of PV modules
 Preventive maintenance such as
cable lug condition check, junction
box fuse inspection etc.
 Safety guidelines and PPE shall be
available at site

− Arrangements for Generation Data  Online monitoring of plant


Collection through remote monitoring performance through WMS shall be
(applicable for SPV Power Plants having installed at each site individually.
more than 5 kWp capacity)  The generation & weather data will
be recorded and stored on portal and
able to access remotely.

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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 Generation data, cleaning records,


spare part inventory shall be
maintained in Daily/ Monthly solar
log book.

3.4. Project Duration and Implementation Schedule [D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 20.2


2 Inverters 6 5.0
3 Module Mounting Structures 4 3.4
4 Electrical wires 5 4.2
5 Net Metering and other approval 2 1.7
6 BOS 5 4.2
7 Installation & Commissioning 4 3.4
8 O&M Cost for 5 Years 5 4.2
Total Cost 55 46.2

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4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.
A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

PV Module type : Multi crystalline


Make : CEL
Model : PM320

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm
Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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Nominal AC Output Power, Pac : 50 kW


Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.

Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 142.5
MWh/year, with Specific Energy Yield of 1674 kWh/KWp/year and performance ratio of 78.42 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 199.5 26.4 25.39 234.9 224.2 16.34 16.05 0.802
February 192.4 31.89 26.47 214.5 204.7 14.82 14.55 0.797
March 211.1 56.51 28.24 219.9 208.9 15.09 14.82 0.792
April 201.5 75.22 29.5 197.6 187.2 13.56 13.32 0.792
May 190.6 80.16 30.42 178 167.9 12.21 12 0.792
June 136.5 83.52 28.69 127 119.3 8.87 8.73 0.808
July 135 84.65 28.58 126.9 119.3 8.88 8.73 0.808
August 138.4 82.03 27.92 133.7 125.8 9.35 9.19 0.808
September 134.7 66.15 27.51 135.6 128.1 9.45 8.55 0.741
October 163.4 75.34 27.09 174.4 165.4 12.22 10.87 0.732
November 153.4 55.86 25.86 173 164.5 12.18 11.97 0.813
December 184.6 28.93 25.23 219.6 210 15.42 13.75 0.736
Year 2041.1 746.66 27.58 2135.1 2025.4 148.39 142.53 0.784

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Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-NAL (KODIHALLI), BENGALURU

National Aerospace Laboratories (NAL), Bengaluru,


Karnataka
Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 383 KWp.
3 Project Location Kodihalli , Bengaluru , Karnataka
a) Site Name CSIR-National Aerospace Laboratories,
Kodihalli (CSIR-NAL)
b) State Karnataka
e) District Bengaluru
f) Latitude 12°56’46” N
g) Longitude 77°40’01” E
h) Altitude 920 Mtr.
4 Connectivity
a) Nearest Railway Station KSR-Railway Station, Bengaluru

b) Nearest Airport Kempegowda International Airport


5 Roof Details
a) Total Area Available (Unshaded) 4600 Sq. M

b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 508.6 MWh
annum
b) CUF 19.18%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 508.6 MWh
b) Total Saving (first year) Rs. 77.20 Lakh
c) Total Saving (25 years) Rs. 19.30 Cr

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 383 KWp
DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 383 KWp Solar Rooftop Power Plant, National Aerospace
Laboratories, Kodihalli, Bengaluru.

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
National Aerospace Laboratories, Kodihalli, Bengaluru.

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3. All Information as per Form B

3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at National
Aerospace Laboratories, Kodihalli
(CSIR-NAL)
2. Capacity of the plant (kWp) 383 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. R. Ravindran
Designation Principle Scientist & Head
Mobile Number
9902540256
E-mail
ravindran@nal.res.in
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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3 Details of Proposed Power Plant


a) Proposed capacity of the SPV Power Plant (KWp) 383 KWp
b) Plant proposed at single site/multiple Single Site
c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 380 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
4600 SQM. So Total Proposed
Capacity of plant is 380 KWp.

g) Expected annual energy generation 643.4 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as
per electricity bill) 1600 KVA
(ii) Applicable consumer category
(domestic/commercial/individual/ others) Commercial
(iii) Total electrical load to be met by the SPV
power plant (kW) 380 KW

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 1197 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)
5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation
axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A & RPI M30A
(kVA) (Details of quality of output power, standards) Capacity – 50 Kw & 30 Kw
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%
8. Number of PCU/inverters proposed to be used 8(50 KW X 7 & 30 KW X 1)
9. DC Bus voltage 1000 V

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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10. Capacity of battery bank (Current, Voltage and AH), if Not Applicable
used, any
11. Type of battery proposed (lead acid tubular/ lithium Not Applicable
ion/ NaS/ any other)
12. Details of protections to be deployed on PV array and SPD, DC isolator, DC MCB, AC MCB,
AC output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging
points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure
16. Details of building to install the Electronics Control Existing ACDB Room
Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as control
room
(ii) If a new building is to be constructed, area, estimated
cost, and etc. to be provided and time frame to
construct the building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual
and schedule to be prepared by the EPC
contractor. Some indicative standard practice
are as follows:
 Periodic cleaning of PV modules

 Preventive maintenance such as


cable lug condition check, junction
box fuse inspection etc.
 Safety guidelines and PPE shall be
available at site

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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− Arrangements for Generation Data  Online monitoring of plant


Collection through remote monitoring performance through WMS shall be
(applicable for SPV Power Plants having installed at each site individually.
more than 5 kWp capacity)  The generation & weather data will
be recorded and stored on portal and
able to access remotely.
 Generation data, cleaning records,
spare part inventory shall be
maintained in Daily/ Monthly solar
log book.

3.4. Project Duration and Implementation Schedule [D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 91.9


2 Inverters 6 23.0
3 Module Mounting Structures 4 15.3
4 Electrical wires 4 15.3
5 Net Metering and other approval 2 7.7
6 BOS 4 15.3
7 Installation & Commissioning 4 15.3
8 O&M Cost for 5 Years 5 19.2
Total Cost 53 203.0

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

PV Module type : Multi crystalline


Make : CEL
Model : PM320

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm
Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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Nominal AC Output Power, Pac : 50 kW


Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.
Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
(CSIR-NAL), Bengaluru, Karnataka

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 634.4
MWh/year, with Specific Energy Yield of 1680 kWh/KWp/year and performance ratio of 78.77 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 199.4 26.39 25.39 234.9 224.2 73.51 67.69 0.752
February 192.4 31.9 26.47 214.5 204.7 66.63 65.55 0.798
March 210.8 56.89 28.24 219.6 208.5 67.77 66.69 0.793
April 201.4 75.33 29.5 197.5 187.1 60.98 56.27 0.744
May 190.7 80.76 30.52 177.9 167.7 54.87 54.04 0.793
June 137 83.02 28.69 127.4 119.8 40.04 39.44 0.808
July 135 77.48 28.59 126.4 119 39.68 39.08 0.807
August 138.5 93.02 27.92 133.7 125.7 42.25 41.63 0.813
September 134.7 76.71 27.5 135.1 127.4 42.46 41.82 0.808
October 163.1 76.47 26.99 173.5 164.4 54.73 49.17 0.74
November 153.3 55.5 25.76 172.5 164.1 54.59 53.74 0.813
December 184.5 29.56 25.13 219.4 209.8 69.32 68.23 0.812
Year 2040.8 763.02 27.56 2132.4 2022.4 666.82 643.37 0.788

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Detailed Project Report of Solar Rooftop PV System at National Aerospace Laboratories
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Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-CFTRI, MYSORE

Central Food Technological Research Institute (CFTRI),


Mysore, Karnataka
Detailed Project Report of Solar Rooftop PV System at Central Food Technological
Research Institute (CSIR-CFTRI), Mysore, Karnataka

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
Research Institute (CSIR-CFTRI), Mysore, Karnataka

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 744 KWp.
3 Project Location Mysore , Karnataka
a) Site Name Central Food Technological Research
Institute (CSIR-CFTRI)
b) State Karnataka
e) District Mysore
f) Latitude 12°18’56”N
g) Longitude 76°38’14”E
h) Altitude 1929 Mtr.
4 Connectivity
a) Nearest Railway Station Mysore Railway Station

b) Nearest Airport Mysore Airport

5 Roof Details
a) Total Area Available (Unshaded) 8926.92 Sq. M

b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 1272 MWh
annum
b) CUF 19.54 %
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 1272 MWh
b) Total Saving (first year) Rs. 89.02 Lakh
c) Total Saving (25 years) Rs. 22.25 Cr

2|Page
Detailed Project Report of Solar Rooftop PV System at Central Food Technological
Research Institute (CSIR-CFTRI), Mysore, Karnataka

2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 744 KWp
DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 744 KWp Solar Rooftop Power Plant, Central Food Technological
Research Institute Mysore, Karnataka

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
Research Institute (CSIR-CFTRI), Mysore, Karnataka

o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
Central Food Technological Research Institute Mysore, Karnataka

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
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3. All Information as per Form B

3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at Central Food
Technological Research
Institute (CSIR-CFTRI)
2. Capacity of the plant (kWp) 744 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. M.N Keshava Prakash
Designation Principle Scientist & Head
Mobile Number
9902238169
E-mail
Keshav@cftri.res.in
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify

7. Any Other detail relevant for consideration of


support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
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Head of the organization


Name of the contact person
Full address, phone, mobile and e-mail
3 Details of Proposed Power Plant
a) Proposed capacity of the SPV Power Plant (KWp) 744 KWp
b) Plant proposed at single site/multiple Single Site
c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 750 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
8926.92 SQM. So Total Proposed
Capacity of plant is 744 KWp.

g) Expected annual energy generation 1272 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as
per electricity bill) 860 KVA
(ii) Applicable consumer category
(domestic/commercial/individual/ others) Commercial
(iii) Total electrical load to be met by the SPV
power plant (kW) 750 KW

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 2318 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)

5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation


axis/ double axis tracking etc.)

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
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6. PCU/inverter capacity with detailed specifications Delta RPI M50 A


(kVA) (Details of quality of output power, standards) Capacity – 50 kW
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%

8. Number of PCU/inverters proposed to be used 15

9. DC Bus voltage 1000 V

10. Capacity of battery bank (Current, Voltage and AH), if Not Applicable
used, any

11. Type of battery proposed (lead acid tubular/ lithium Not Applicable
ion/ NaS/ any other)
12. Details of protections to be deployed on PV array and SPD, DC isolator, DC MCB, AC MCB,
AC output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging
points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure
16. Details of building to install the Electronics Control Existing ACDB Room
Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as control
room
(ii) If a new building is to be constructed, area, estimated
cost, and etc. to be provided and time frame to
construct the building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual
and schedule to be prepared by the EPC
contractor. Some indicative standard practice
are as follows:
 Periodic cleaning of PV modules
 Preventive maintenance such as
cable lug condition check, junction
box fuse inspection etc.

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
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 Safety guidelines and PPE shall be


available at site

− Arrangements for Generation Data  Online monitoring of plant


Collection through remote monitoring performance through WMS shall be
(applicable for SPV Power Plants having installed at each site individually.
more than 5 kWp capacity)  The generation & weather data will
be recorded and stored on portal and
able to access remotely.
 Generation data, cleaning records,
spare part inventory shall be
maintained in Daily/ Monthly solar
log book.

3.4. Project Duration and Implementation Schedule[D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
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1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
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4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
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3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 178.6


2 Inverters 6 44.6
3 Module Mounting Structures 4 29.8
4 Electrical wires 4 29.8
5 Net Metering and other approval 2 14.9
6 BOS 4 29.8
7 Installation & Commissioning 4 29.8
8 O&M Cost for 5 Years 5 37.2
Total Cost 53 394.3

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4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.
A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
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Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
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5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

PV Module type : Multi crystalline


Make : CEL
Model : PM320

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
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Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm
Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
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Nominal AC Output Power, Pac : 50 kW


Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.

Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
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inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

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Detailed Project Report of Solar Rooftop PV System at Central Food Technological
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Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 1272
MWh/year, with Specific Energy Yield of 1714 kWh/KWp/year and performance ratio of 79.75 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 200.6 26.39 26.31 235.6 227.1 143.6 141.7 0.811
February 193.9 32.41 27.38 215.5 207.8 130.5 128.7 0.805
March 213 57.12 29.13 221.5 212.6 133.4 122.4 0.745
April 199.8 72.58 29.79 195.2 186.8 117.9 116.2 0.803
May 190.1 80.1 29.49 177.8 169.5 108 96.5 0.732
June 132.5 79.79 26.85 123.2 117 76.5 75.3 0.823
July 133.7 83.64 26.62 125.2 118.8 77.9 70.3 0.757
August 138.9 92.66 26.26 134.2 127.5 83.6 82.4 0.827
September 140.2 81.2 26.21 141.4 134.8 87.7 86.4 0.824
October 167.7 69.3 26.79 178.5 171.1 109.8 108.3 0.818
November 154.7 63.78 26.64 173.5 166.4 107.3 105.8 0.822
December 192 27.18 26.32 228.2 220.4 139.7 137.8 0.814
Year 2057 766.14 27.31 2149.8 2059.7 1315.9 1271.7 0.798

21 | P a g e
Detailed Project Report of Solar Rooftop PV System at Central Food Technological
Research Institute (CSIR-CFTRI), Mysore, Karnataka

Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

22 | P a g e
DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-CCMB, HYDERABAD

Centre of Cellular & Molecular Biology (CCMB),


Hyderabad, Telangana
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

1|Page
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 185 KWp.
3 Project Location Hyderabad, Telangana
a) Site Name Centre of Cellular & Molecular Biology
(CSIR-CCMB)
b) State Telangana
e) District Hyderabad
f) Latitude 17.4211189 N
g) Longitude 78.5414585 E
h) Altitude 505 Mtr.
4 Connectivity
a) Nearest Railway Station Secunderabad Railway Station

b) Nearest Airport Rajiv Gandhi International Airport

5 Roof Details
a) Total Area Available (Unshaded) 2220 Sq. M

b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 279.8 MWh
annum
b) CUF 18.05%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 279.8 MWh
b) Total Saving (first year) Rs. 27.98 Lakh
c) Total Saving (25 years) Rs. 7.00 Cr

2|Page
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 185 KWp
DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 177 KWp Solar Rooftop Power Plant, Centre for Cellular & Molecular
Biology, Hyderabad, Telangana.

3|Page
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
Centre for Cellular & Molecular Biology, Hyderabad, Telangana .

4|Page
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

3. All Information as per Form B

3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at Centre for
Cellular & Molecular Biology (CSIR-
CCMB)
2. Capacity of the plant (kWp) 185 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. A. Varaprasad Rao
Designation AEE
Mobile Number
8121382811
E-mail
varaprasad@ccmb.res.in
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail

5|Page
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

3 Details of Proposed Power Plant


a) Proposed capacity of the SPV Power Plant (KWp) 185 KWp
b) Plant proposed at single site/multiple Single Site
c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 180 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
2122 SQM. So Total Proposed
Capacity of plant is 177 KWp.

g) Expected annual energy generation 279.8 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as
per electricity bill) 1500 KVA
(ii) Applicable consumer category
(domestic/commercial/individual/ others) Commercial
(iii) Total electrical load to be met by the SPV
power plant (kW) 180 KW

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 578 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)

5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation


axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A & RPI M30 A
(kVA) (Details of quality of output power, standards) Capacity – 50 Kw & 30 Kw

6|Page
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

7. Type of inverter (central/ string/ multi string/any String inverter


other), inverter efficiency Inverter efficiency – 98.4%
8. Number of PCU/inverters proposed to be used 4 (50 KW X 3 & 30 KW X 1)

9. DC Bus voltage 1000 V

10. Capacity of battery bank (Current, Voltage and AH), if Not Applicable
used, any

11. Type of battery proposed (lead acid tubular/ lithium Not Applicable
ion/ NaS/ any other)
12. Details of protections to be deployed on PV array and SPD, DC isolator, DC MCB, AC MCB,
AC output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging
points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure
16. Details of building to install the Electronics Control Existing ACDB Room
Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as control
room
(ii) If a new building is to be constructed, area, estimated
cost, and etc. to be provided and time frame to
construct the building

3.3. Operation and Maintenance Arrangements [C]

S .no Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual
and schedule to be prepared by the EPC
contractor. Some indicative standard practice
are as follows:
 Periodic cleaning of PV modules
 Preventive maintenance such as
cable lug condition check, junction
box fuse inspection etc.

7|Page
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

 Safety guidelines and PPE shall be


− Arrangements for Generation Data available at site
Collection through remote monitoring
(applicable for SPV Power Plants having  Online monitoring of plant
more than 5 kWp capacity) performance through WMS shall be
installed at each site individually.
 The generation & weather data will
be recorded and stored on portal and
able to access remotely.
 Generation data, cleaning records,
spare part inventory shall be
maintained in Daily/ Monthly solar
log book.

3.4. Project Duration and Implementation Schedule [D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

8|Page
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

9|Page
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

10 | P a g e
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 44.4


2 Inverters 6 11.1
3 Module Mounting Structures 4 7.4
4 Electrical wires 4 7.4
5 Net Metering and other approval 2 3.7
6 BOS 4 7.4
7 Installation & Commissioning 4 7.4
8 O&M Cost for 5 Years 5 9.3
Total Cost 53 98.1

11 | P a g e
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

12 | P a g e
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.
A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

13 | P a g e
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

Figure 1 Typical Solar PV System diagram

14 | P a g e
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

PV Module type : Multi crystalline


Make : CEL
Model : PM320

15 | P a g e
Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm
Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V

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Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

Nominal AC Output Power, Pac : 50 kW


Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.

Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to

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Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

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Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter

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Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 279.8
MWh/year, with Specific Energy Yield of 1587 kWh/KWp/year and performance ratio of 78.51 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 149.6 53.03 23.69 182.6 174 26.87 26.45 0.821
February 159.2 51.52 26.48 184.3 175.5 26.57 26.15 0.805
March 185.3 75.81 29.69 196.5 186.3 27.85 27.41 0.791
April 190.7 77.67 32.31 188.4 178.6 26.38 25.95 0.781
May 197.8 87.84 33.93 182.7 172.4 25.5 25.09 0.779
June 156.5 96.2 29.84 143 134.7 20.62 20.31 0.805
July 139.6 90.52 28.23 129.4 121.7 18.81 18.53 0.812
August 145 86.76 26.87 139.3 131.4 20.32 20 0.814
September 152.5 80.59 27 155.5 147.2 22.59 19.57 0.714
October 157.6 73.62 26.7 172.9 164.2 25.12 24.73 0.811
November 138.2 55.29 24.39 163.9 155.6 23.99 21.14 0.732
December 145.8 47.67 23.01 182.9 174.3 26.96 24.5 0.76
Year 1917.9 876.52 27.68 2021.3 1915.8 291.59 279.82 0.785

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Detailed Project Report of Solar Rooftop PV System at Centre of Cellular & Molecular
Biology (CSIR-CCMB), Hyderabad, Telangana.

Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-IICT, HYDERABAD

Indian Institute of Chemical Technology (IICT),


Hyderabad, Telangana
Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

1|Page
Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 333 KWp.
3 Project Location Hyderabad, Telangana
a) Site Name Indian Institute of Chemical Technology
(CSIR-IICT)
b) State Telangana
e) District Hyderabad
f) Latitude 17.4231194 N
g) Longitude 78.5397222 E
h) Altitude 505 Mtr.
4 Connectivity
a) Nearest Railway Station Secunderabad Railway Station

b) Nearest Airport Rajiv Gandhi International Airport

5 Roof Details
a) Total Area Available (Unshaded) 3992 Sq. M

b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 535.5 MWh
annum
b) CUF 18.36%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 535.5 MWh
b) Total Saving (first year) Rs. 44.23 Lakh
c) Total Saving (25 years) Rs.11.06 Cr

2|Page
Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 333 KWp
DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 333 KWp Solar Rooftop Power Plant, Indian Institute of Chemical
Technology, Hyderabad,Telangana.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
Indian Institute of Chemical Technology, Hyderabad,Telangana.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

3. All Information as per Form B

3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at Indian Institute
of Chemical Technology (CSIR-IICT)
2. Capacity of the plant (kWp) 333 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. Narsingh Yadav
Designation Sr. Technical Officer
Mobile Number 09849296677
E-mail
NA
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail
3 Details of Proposed Power Plant
a) Proposed capacity of the SPV Power Plant (KWp) 333 KWp

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

b) Plant proposed at single site/multiple Single Site


c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 330 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
3992 SQM. So Total Proposed
Capacity of plant is 333 KWp.

g) Expected annual energy generation 535.5 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as
per electricity bill) 2500 KVA
(ii) Applicable consumer category
(domestic/commercial/individual/ others) Commercial
(iii) Total electrical load to be met by the SPV
power plant (kW) 330 KW

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 1045 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)

5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation


axis/ double axis tracking etc.)

6. PCU/inverter capacity with detailed specifications Delta RPI M50 A & M30 A
(kVA) (Details of quality of output power, standards) Capacity – 50 Kw & 30 Kw

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

7. Type of inverter (central/ string/ multi string/any String inverter


other), inverter efficiency Inverter efficiency – 98.4%

8. Number of PCU/inverters proposed to be used 7( 50 KW X 6 & 30 KW X 1)

9. DC Bus voltage 1000 V

10. Capacity of battery bank (Current, Voltage and AH), if Not Applicable
used, any
11. Type of battery proposed (lead acid tubular/ lithium Not Applicable
ion/ NaS/ any other)

12. Details of protections to be deployed on PV array and SPD, DC isolator, DC MCB, AC MCB,
AC output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging
points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure

16. Details of building to install the Electronics Control Existing ACDB Room
Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as control
room
(ii) If a new building is to be constructed, area, estimated
cost, and etc. to be provided and time frame to
construct the building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual
and schedule to be prepared by the EPC
contractor. Some indicative standard practice
are as follows:
 Periodic cleaning of PV modules
 Preventive maintenance such as
cable lug condition check, junction
box fuse inspection etc.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

 Safety guidelines and PPE shall be


available at site

− Arrangements for Generation Data  Online monitoring of plant


Collection through remote monitoring performance through WMS shall be
(applicable for SPV Power Plants having installed at each site individually.
more than 5 kWp capacity)  The generation & weather data will
be recorded and stored on portal and
able to access remotely.

 Generation data, cleaning records,


spare part inventory shall be
maintained in Daily/ Monthly solar
log book.

3.4. Project Duration and Implementation Schedule [D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

8|Page
Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure
2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 79.9


2 Inverters 6 20.0
3 Module Mounting Structures 4 13.3
4 Electrical wires 4 13.3
5 Net Metering and other approval 2 6.7
6 BOS 4 13.3
7 Installation & Commissioning 4 13.3
8 O&M Cost for 5 Years 5 16.7
Total Cost 53 176.5

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.
A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

PV Module type : Multi crystalline


Make : CEL
Model : PM320

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm
Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

Nominal AC Output Power, Pac : 50 kW


Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.

Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to
inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 535.5
MWh/year, with Specific Energy Yield of 1601 kWh/KWp/year and performance ratio of 79.22 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 149.6 53.03 23.69 182.6 174 50.95 46.34 0.759
February 159.2 51.52 26.48 184.3 175.5 50.38 49.71 0.807
March 185.3 75.81 29.69 196.5 186.3 52.82 49.28 0.75
April 190.7 77.67 32.31 188.4 178.6 50.02 49.32 0.783
May 197.8 87.84 33.93 182.7 172.4 48.36 47.69 0.781
June 156.5 96.2 29.84 143 134.7 39.11 38.54 0.806
July 139.6 90.52 28.23 129.4 121.7 35.68 32.16 0.744
August 145 86.75 26.87 139.3 131.4 38.53 37.94 0.815
September 152.4 80.59 27 155.5 147.2 42.83 42.2 0.812
October 157.6 73.62 26.7 172.9 164.2 47.64 46.95 0.812
November 138.2 55.29 24.39 163.9 155.6 45.5 44.89 0.819
December 145.8 47.67 23.01 182.9 174.3 51.13 50.44 0.825
Year 1917.9 876.5 27.68 2021.4 1915.9 552.95 535.49 0.792

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Chemical
Technology (CSIR-IICT), Hyderabad, Telangana

Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-NGRI, HYDERABAD

National Geophysics Research Institute (NGRI),


Hyderabad, Telangana
Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
(CSIR-NGRI), Hyderabad, Telangana

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
(CSIR-NGRI), Hyderabad, Telangana

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 253 KWp.
3 Project Location Uppal Road, Habsiguda, Hyderabad
a) Site Name National Geophysics Research Institute
(CSIR-NGRI)
b) State Telangana
e) District Hyderabad
f) Latitude 17.415858 N
g) Longitude 78.552009 E
h) Altitude 505 Mtr. above MSL
4 Connectivity
a) Nearest Railway Station Secunderabad Railway Station

b) Nearest Airport Rajiv Gandhi International Airport

5 Roof Details
a) Total Area Available (Unshaded) 3032 Sq. M

b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 398.2 MWh
annum
b) CUF 17.96%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 398.2 MWh
b) Total Saving (first year) Rs. 32.89 Lakh
c) Total Saving (25 years) Rs. 8.22 Cr

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
(CSIR-NGRI), Hyderabad, Telangana

2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 253 KWp
DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 253 KWp Solar Rooftop Power Plant, National Geophysics Research
Institute, Hyderabad, Telangana.

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
(CSIR-NGRI), Hyderabad, Telangana

o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
National Geophysics Research Institute, Hyderabad, Telangana.

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
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3. All Information as per Form B


3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at National
Geophysics Research Institute (CSIR-
NGRI)
2. Capacity of the plant (kWp) 253 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. Brabhakar
Designation Principle Technical Officier
Mobile Number 9441264153
E-mail amsbrabhakar@yahoo.com
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail
3 Details of Proposed Power Plant

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
(CSIR-NGRI), Hyderabad, Telangana

a) Proposed capacity of the SPV Power Plant (KWp) 253 KWp


b) Plant proposed at single site/multiple Single Site
c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 250 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
3032 SQM. So Total Proposed
Capacity of plant is 253 KWp.

g) Expected annual energy generation 398.2 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as
per electricity bill) 1000 KVA
(ii) Applicable consumer category
(domestic/commercial/individual/ others) Commercial
(iii) Total electrical load to be met by the SPV
power plant (kW) 250 KW

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 779 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)
5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation
axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A
(kVA) (Details of quality of output power, standards) Capacity – 50 kW
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%
8. Number of PCU/inverters proposed to be used 5
9. DC Bus voltage 1000 V

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
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10. Capacity of battery bank (Current, Voltage and AH), if Not Applicable
used, any
11. Type of battery proposed (lead acid tubular/ lithium Not Applicable
ion/ NaS/ any other)
12. Details of protections to be deployed on PV array and SPD, DC isolator, DC MCB, AC MCB,
AC output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging
points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure
16. Details of building to install the Electronics Control Existing ACDB Room
Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as control
room
(ii) If a new building is to be constructed, area, estimated
cost, and etc. to be provided and time frame to
construct the building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual
and schedule to be prepared by the EPC
contractor. Some indicative standard practice
are as follows:
 Periodic cleaning of PV modules
 Preventive maintenance such as
cable lug condition check, junction
box fuse inspection etc.
 Safety guidelines and PPE shall be
available at site

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
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− Arrangements for Generation Data  Online monitoring of plant


Collection through remote monitoring performance through WMS shall be
(applicable for SPV Power Plants having installed at each site individually.
more than 5 kWp capacity)  The generation & weather data will
be recorded and stored on portal and
able to access remotely.
 Generation data, cleaning records,
spare part inventory shall be
maintained in Daily/ Monthly solar
log book.

3.4. Project Duration and Implementation Schedule[D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
(CSIR-NGRI), Hyderabad, Telangana

1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
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4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
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3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 60.7


2 Inverters 6 15.2
3 Module Mounting Structures 4 10.1
4 Electrical wires 4 10.1
5 Net Metering and other approval 2 5.1
6 BOS 4 10.1
7 Installation & Commissioning 4 10.1
8 O&M Cost for 5 Years 5 12.7
Total Cost 53 134.1

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4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.
A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
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Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
(CSIR-NGRI), Hyderabad, Telangana

5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

PV Module type : Multi crystalline


Make : CEL
Model : PM320

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
(CSIR-NGRI), Hyderabad, Telangana

Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm
Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
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Nominal AC Output Power, Pac : 50 kW


Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.

Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to

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inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
(CSIR-NGRI), Hyderabad, Telangana

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at National Geophysics Research Institute
(CSIR-NGRI), Hyderabad, Telangana

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 398.2
MWh/year, with Specific Energy Yield of 1597 kWh/KWp/year and performance ratio of 79.00 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 149.6 53.05 23.69 182.6 174 37.98 37.43 0.822
February 159.2 51.56 26.48 184.3 175.4 37.55 37 0.805
March 185.3 75.86 29.69 196.5 186.3 39.37 36.57 0.747
April 190.7 77.71 32.31 188.3 178.5 37.28 36.7 0.782
May 197.7 87.88 33.93 182.6 172.3 36.03 35.48 0.78
June 156.5 96.23 29.84 143 134.6 29.15 28.74 0.806
July 139.7 90.47 28.23 129.4 121.8 26.6 26.22 0.813
August 145.1 92.9 26.87 139.3 131.4 28.8 28.39 0.818
September 152.5 80.21 27 155.1 146.8 31.87 28.65 0.741
October 157.6 69.24 26.7 173.4 164.9 35.54 31.89 0.738
November 138.3 52.22 24.39 164.6 156.5 34.05 33.55 0.818
December 145.8 48.97 23.01 182.6 173.9 38.08 37.53 0.825
Year 1917.9 876.3 27.68 2021.7 1916.3 412.3 398.15 0.79

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Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-CECRI, KARAIKUDI

Central Electrochemical Research Institute (CECRI),


Karaikudi, Tamil Nadu
Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 315 KWp.
3 Project Location
a) Site Name Central Electrochemical Research
Institute (CSIR-CECRI)
b) State Tamil Nadu
e) District Karaikudi
f) Latitude 10.08N
g) Longitude 78.78E
h) Altitude 82 Mtr. above MSL
4 Connectivity
a) Nearest Railway Station
Karaikudi Railway Station

b) Nearest Airport Trichy Airport (approx. 90 KMs)

5 Roof Details
a) Total Area Available (Unshaded)
3770 Sq. M

b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 508.6 MWh
annum
b) CUF 18.31%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 508.6 MWh
b) Total Saving (first year) Rs. 32.29 Lakh
c) Total Saving (25 years) Rs. 8.07 Cr

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 315 KWp
DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 315 KWp Solar Rooftop Power Plant, Central Electrochemical
Research Institute, Karaikudi, Tamil Nadu.

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
Central Electrochemical Research Institute, Karaikudi, Tamil Nadu.

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
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3. All Information as per Form B

3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at at Central
Electrochemical Research Institute
(CSIR-CECRI)
2. Capacity of the plant (kWp) 315 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. G. Sozhan
Designation Chief Scientist & Head
Mobile Number
9843182678
E-mail
sozhan@cecri.res.in
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
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3 Details of Proposed Power Plant


a) Proposed capacity of the SPV Power Plant (KWp) 315 KWp
b) Plant proposed at single site/multiple Single Site
c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 300 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
3770 SQM. So Total Proposed
Capacity of plant is 315 KWp.

g) Expected annual energy generation 508.6 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as
per electricity bill) 500 KVA & 400 KVA
(ii) Applicable consumer category
(domestic/commercial/individual/ others) Commercial
(iii) Total electrical load to be met by the SPV
power plant (kW) 300 KW

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 990 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)
5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation
axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A
(kVA) (Details of quality of output power, standards) Capacity – 50 kW
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%
8. Number of PCU/inverters proposed to be used 6
9. DC Bus voltage 1000 V

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
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10. Capacity of battery bank (Current, Voltage and AH), if used, Not Applicable
any
11. Type of battery proposed (lead acid tubular/ lithium ion/ Not Applicable
NaS/ any other)
12. Details of protections to be deployed on PV array and AC SPD, DC isolator, DC MCB, AC MCB,
output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging operation The data logger takes care of
data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging points to
be provided.
15. Details of Mounting system: Roof-top mounting system with Fixed
- Roof mounted system Tilt Hot dip galvanized structure
- Ground mounted system
16. Details of building to install the Electronics Control Panel Existing ACDB Room
and Battery Bank (if any)
(i) Whether any existing building is to be used as control room
(ii) If a new building is to be constructed, area, estimated cost,
and etc. to be provided and time frame to construct the
building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual and
schedule to be prepared by the EPC contractor.
Some indicative standard practice are as follows:
 Periodic cleaning of PV modules
 Preventive maintenance such as cable
lug condition check, junction box fuse
inspection etc.
 Safety guidelines and PPE shall be
available at site

 Online monitoring of plant performance


− Arrangements for Generation Data Collection through WMS shall be installed at each
through remote monitoring (applicable for SPV site individually.
Power Plants having more than 5 kWp capacity)  The generation & weather data will be
recorded and stored on portal and able
to access remotely.
 Generation data, cleaning records, spare
part inventory shall be maintained in
Daily/ Monthly solar log book.

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
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3.4. Project Duration and Implementation Schedule[D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
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The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 75.6


2 Inverters 6 18.9
3 Module Mounting Structures 4 12.6
4 Electrical wires 4 12.6
5 Net Metering and other approval 2 6.3
6 BOS 4 12.6
7 Installation & Commissioning 4 12.6
8 O&M Cost for 5 Years 5 15.8
Total Cost 53 167.0

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.
A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

PV Module type : Multi crystalline


Make : CEL
Model : PM320

Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V
Nominal AC Output Power, Pac : 50 kW
Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.
Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to
inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 508.6
MWh/year, with Specific Energy Yield of 1605 kWh/KWp/year and performance ratio of 80.04 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 162.9 63.06 25.67 178 170.4 47.13 46.37 0.82
February 164.2 57.68 27.2 174.6 167.2 45.48 44.71 0.81
March 192.8 74.37 29.54 197.3 188.8 50.79 49.91 0.80
April 182.5 70.78 30.87 180 172 46.06 45.25 0.79
May 177.8 77.83 31.61 169.7 161.5 43.48 42.74 0.80
June 145.4 80.44 30.77 138 131.1 35.7 35.12 0.80
July 156.7 89.47 30.99 149.7 142.2 38.73 38.11 0.80
August 168.0 83.39 30.25 163.5 155.7 42.31 41.61 0.80
September 164.1 72.12 29.29 165.3 157.7 42.79 42.06 0.80
October 156.3 74.54 28.2 162.8 155.5 42.56 41.86 0.81
November 133.4 72.51 26.08 142.3 135.6 37.81 37.22 0.83
December 151.9 55.97 25.49 167.1 160.2 44.31 43.58 0.82
Year 1955.9 872.17 28.84 1988.3 1897.8 517.13 508.56 0.81

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Detailed Project Report of Solar Rooftop PV System at Central Electrochemical Research
Institute (CSIR-CECRI), Karaikudi, Tamil Nadu

Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-SERC, CHENNAI.

Structural Engineering Research Centre (SERC),


Taramani, Tamil Nadu
Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
Centre CSIR-SERC, Chennai Tamil Nadu

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
Centre CSIR-SERC, Chennai Tamil Nadu

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 435 KWp
3 Project Location Chennai, Tamil Nadu
a) Site Name CSIR – Structural Engineering Research
Centre (CSIR-SERC)
b) State Tamil Nadu
e) District Taramani
f) Latitude 12.98N
g) Longitude 80.24E
h) Altitude 82 Mtr. above MSL
4 Connectivity
a) Nearest Railway Station Thiruvanmiyur Railway Station

b) Nearest Airport Chennai Airport


5 Roof Details
a) Total Area Available (Unshaded) 5254 Sq.m.
b) Nature of Roof
Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point
415 V Busbar at Existing LT Panel Room
7 Energy generated
a) Estimated Net Energy Generation per
695.5 MWh
annum
b) CUF 18.25%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 695.5 MWh
b) Total Saving (first year) Rs. 62.59 Lakh
c) Total Saving (25 years) Rs. 15.65 Cr

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
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2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 435 KWp
DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 435 KWp Solar Rooftop Power Plant, Central Electrochemical
Research Institute, Karaikudi, Tamil Nadu.

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
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o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
Central Electrochemical Research Institute, Karaikudi, Tamil Nadu.

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
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3. All Information as per Form B

3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at CSIR – Structural
Engineering Research Centre (CSIR-SERC)
2. Capacity of the plant (kWp) 435KWp
3. Category of the Applicant/Project Proponent Government Organization
4. Details of the Project Proponent
Name Mr. B. Natarajan
Designation Asst. Executive Engineer
Mobile Number 9884945567
E-mail bnatarajan@csircmc.res.in
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail
3 Details of Proposed Power Plant

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
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a) Proposed capacity of the SPV Power Plant (KWp) 435 KWp


b) Plant proposed at single site/multiple Single Site
c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 430 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm/ KWP. and total available area
at the roof to install the plant is
around 5,254 SQM. So Total
Capacity of plant is 435 KWp.

g) Expected annual energy generation 695.5 MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as
per electricity bill) 1500 KVA
(ii) Applicable consumer category
(domestic/commercial/individual/ others) Commercial
(iii) Total electrical load to be met by the SPV
power plant (kW) 430 KW

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 1368 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)
5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation
axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A & Delta RPI M30 A
(kVA) (Details of quality of output power, standards) Capacity – 50 Kw & 30 kw
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%
8. Number of PCU/inverters proposed to be used 9( 50 Kw X 8 & 30 Kw X 1)
9. DC Bus voltage 1000 V

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
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10. Capacity of battery bank (Current, Voltage and AH), if used, Not Applicable
any
11. Type of battery proposed (lead acid tubular/ lithium ion/ Not Applicable
NaS/ any other)
12. Details of protections to be deployed on PV array and AC SPD, DC isolator, DC MCB, AC MCB,
output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging operation The data logger takes care of
data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging points to
be provided.
15. Details of Mounting system: Roof-top mounting system with Fixed
- Roof mounted system Tilt Hot dip galvanized structure
- Ground mounted system
16. Details of building to install the Electronics Control Panel Existing ACDB Room
and Battery Bank (if any)
(i) Whether any existing building is to be used as control room
(ii) If a new building is to be constructed, area, estimated cost,
and etc. to be provided and time frame to construct the
building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual and
schedule to be prepared by the EPC contractor.
Some indicative standard practice are as follows:
 Periodic cleaning of PV modules
 Preventive maintenance such as cable
lug condition check, junction box fuse
inspection etc.
 Safety guidelines and PPE shall be
available at site

 Online monitoring of plant performance


− Arrangements for Generation Data Collection through WMS shall be installed at each
through remote monitoring (applicable for SPV site individually.
Power Plants having more than 5 kWp capacity)  The generation & weather data will be
recorded and stored on portal and able
to access remotely.
 Generation data, cleaning records, spare
part inventory shall be maintained in
Daily/ Monthly solar log book.

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
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3.4. Project Duration and Implementation Schedule[D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
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3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
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The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 104.4


2 Inverters 6 26.1
3 Module Mounting Structures 4 17.4
4 Electrical wires 4 17.4
5 Net Metering and other approval 2 8.7
6 BOS 4 17.4
7 Installation & Commissioning 4 17.4
8 O&M Cost for 5 Years 5 21.8
Total Cost 53 230.6

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
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4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.
A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
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Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
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5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

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PV Module type : Multi crystalline


Make : CEL
Model : PM320

Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
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Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V
Nominal AC Output Power, Pac : 50 kW
Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.
Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
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LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to
inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

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Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
Centre CSIR-SERC, Chennai Tamil Nadu

6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
Centre CSIR-SERC, Chennai Tamil Nadu

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 695.5
MWh/year, with Specific Energy Yield of 1589 kWh/KWp/year and performance ratio of 80.93 %.
The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 149.6 59.61 25 166.9 160.7 61.75 60.84 0.833
February 164.6 56.25 26.09 179 172.6 65.51 64.52 0.824
March 196.1 69.28 27.96 202.7 195.3 73.13 71.98 0.811
April 194.1 73.23 29.58 191.9 184.2 68.87 67.81 0.807
May 192.6 83.57 31.63 183.7 176 65.42 64.43 0.801
June 169.2 88.78 30.62 159.6 152.7 57.54 56.7 0.811
July 161.2 89.7 30.34 153.2 146.4 55.29 49.98 0.745
August 162.3 88.36 29.38 158.3 151.4 57.29 56.46 0.815
September 160.7 74.43 28.7 162.4 155.9 58.79 55.18 0.776
October 137.4 74.59 27.32 144.2 138.2 52.73 51.94 0.823
November 115.2 68.11 25.46 123.9 118.7 45.97 45.32 0.835
December 123.9 62.7 24.79 137.3 131.8 51.03 50.29 0.837
Year 1926.8 888.61 28.08 1963.1 1883.9 713.33 695.46 0.809

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Detailed Project Report of Solar Rooftop PV System at Structural Engineering Research
Centre CSIR-SERC, Chennai Tamil Nadu

Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-CLRI, CHENNAI

Central Leather Research Institute (CLRI),


Chennai, Tamil Nadu
Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 360 KWp
3 Project Location Chennai , Tamil Nadu
Central Leather Research Institute (CSIR-
a) Site Name
CLRI)
b) State Tamil Nadu
e) District Adyar
f) Latitude 13.00N
g) Longitude 80.24E
h) Altitude 50 Mtrs. above MSL
4 Connectivity

a) Nearest Railway Station Kasturibai Nagar Railway Station

b) Nearest Airport Chennai Airport

5 Roof Details
a) Total Area Available (Unshaded) 4300 Sq.M

b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Busbar at LT Panel
7 Energy generated
Estimated Net Energy Generation per
a) 558.0 MWh
annum
b) Plant Load Factor (PLF) 17.70%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 558.0 MWh
b) Total Saving (first year) Rs. 35.43 Lakh
c) Total Saving (25 years) Rs. 8.86 Cr

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 360 KWp
DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

 Site Survey as per the standard format provided by MNRE.


 Study of the electrical load requirement and captive consumption of the establishment
at the site.
 Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
 Estimate the power generation potential depending on the site conditions.
 Preparation of preliminary Feasibility Report
 Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
 Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
 The consultant shall provide cost estimates associated with the project Detailed
Project Report of 360 KWp Solar Rooftop Power Plant, Central Leather Research
Institute (CSIR-CLRI), Chennai, Tamil Nadu

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.

 The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
 The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
 power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
 Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
 Central Leather Research Institute (CSIR-CLRI),Chennai, Tamil Nadu

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

3. All Information as per Form B


3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at
Central Leather Research
Institute (CSIR-CLRI)
2. Capacity of the plant (kWp) 360 KWp
3. Category of the Applicant/Project Proponent Government Organisation

Details of the Project Proponent Mr. R. Ravisekar


Name Superintending Engineer
Designation
Mobile Number 9840251591
4. E-mail ravisekar@clri.res.in
5. Executive Summary of the Proposal Refer Section 1
Objective for implementing the Plant Self-consumption and diesel
(a) Sale of electricity to the distribution licensee at saving
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
6. (g) Any other, please specify
Any Other detail relevant for consideration of
support under the scheme by the evaluation
7. committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] Same as[A]4
4 above; if No, Address of the location of the
plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Same as [B]1
Project Beneficiary/ Organization
Head of the organization
Name of the contact person

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

Full address, phone, mobile and e-mail


3 Details of Proposed Power Plant
a) Proposed capacity of the SPV Power Plant 360 KWp.
(KWp) Single Site
b) Plant proposed at single site/multiple Single Point
c) Interconnection with the electricity network
at single point or multiple point Yes
d) Availability of shadow free south facing
rooftop/ land area for the power plant 360
e) Total loads to be energized by SPV Power
Plant(KW) As per industry practice the area
f) Calculations and justification for the required per kWp is around 12
proposed capacity (Please elaborate) sqm/ KWP. The total available
area at the roof to install the
plant is around 4300 SQM. So
Total Capacity of plant is 360
Kwp

g) Expected annual energy generation 558 KWH


h) Space for housing the plant control systems NA
and battery bank (if any)

4 Details of electrical load where the plant is to be


installed
(i) Total connected electrical load in KW (as 800 KVA
per electricity bill)
(ii) Applicable consumer category Commercial
(domestic/commercial/individual/ others)
(iii) Total electrical load to be met by the SPV 360 KW
power plant (kW)

5 Technology Description & System


Design/Specification
1. Sketch/Line diagram of the complete SPV Attached
System with details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity 1116 modules & 357 kWp
(nos. & kWp)
4. Solar cell technology and Module efficiency Poly crystalline
proposed to be used (mono-crystalline/ poly- Efficiency – 15.42 %
crystalline/ thin film/ any other)

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

5. Details of Tracking of PV Array, if proposed Fixed tilt installation


(single axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed Delta RPI M50 A
specifications (kVA) (Details of quality of output Capacity – 50 kW
power, standards)
7. Type of inverter (central/ string/ multi String inverter
string/any other), inverter efficiency Inverter efficiency – 98.4%
8. Number of PCU/inverters proposed to be used 7
9. DC Bus voltage 1000 V
10. Capacity of battery bank (Current, Voltage and Not Applicable
AH), if used, any
11. Type of battery proposed (lead acid tubular/ Not Applicable
lithium ion/ NaS/ any other)
12. Details of protections to be deployed on PV SPD, DC isolator, DC MCB, AC
array and AC output side MCB, Fuses, Overcurrent relays,
Reverse power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and
regular data logging of the SPV
system.
14. Schematic diagram of the system including Attached
protecting interlocking devices, monitoring and
data logging points to be provided.
15. Details of Mounting system: Fixed tilt Hot dip galvanized SS
- Roof mounted system structure.
- Ground mounted system
16. Details of building to install the Electronics Existing ACDB Room
Control Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as
control room
(ii) If a new building is to be constructed, area,
estimated cost, and etc. to be provided and time
frame to construct the building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major
Arrangements equipment is tabulated in annexure I &
II. Detail manual and schedule to be
prepared by the EPC contractor. Some

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

indicative standard practice are as


follows:
 Periodic cleaning of PV
modules
 Preventive maintenance such
as cable lug condition check,
junction box fuse inspection
− Arrangements for Generation Data etc.
Collection through remote monitoring  Safety guidelines and PPE shall
(applicable for SPV Power Plants having be available at site
more than 5 kWp capacity)
 Online monitoring of plant
performance through WMS
shall be installed at each site
individually.
 The generation & weather data
will be recorded and stored on
portal and able to access
remotely.
 Generation data, cleaning
records, spare part inventory
shall be maintained in Daily/
Monthly solar log book.

3.4. Project Duration and Implementation Schedule[D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure
2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the suppliers
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.
It is responsibility of the company to ensure that major civil work shall have to be planned in the
non-monsoon period. All the statutory clearances will be obtained much before of the start of
the project commissioning.
Table 1 Work Plan
Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp To be arranged by the EPC
and above) contractor

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project [F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 86.4


2 Inverters 6 21.6
3 Module Mounting Structures 4 14.4
4 Electrical wires 4 14.4
5 Net Metering and other approval 2 7.2
6 BOS 4 14.4
7 Installation & Commissioning 4 14.4
8 O&M Cost for 5 Years 5 18.0
Total Cost 53 190.8

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

4. Rooftop Solar Power Generation System Description

A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.
A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

5. System Description and Specification of the Components


Any solar PV power project consists of following major components

 Solar PV modules
 String Inverters
 Transformers
 Balance of Plant

Figure 2 Typical solar PV system component

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

PV Module type : Multi crystalline


Make : CEL
Model : PM300
Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 300 Wp
Rated Voltage (Vmp) : 35.00 Volts
Rated Current (Imp) : 8.57 Amps
Open Circuit Voltage (V oc) : 45.00 Volts
Short Circuit Current (I sc) : 9.02 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 15.42 %

Electrical Parameter at NOCT : NOCT 45oC 800 W/m², and 20°C


Rated Power : 216.0 Wp
Rated Voltage (Vmp) : 30.80 Volts
Rated Current (Imp) : 7.03 Amps
Open Circuit Voltage (V oc) : 39.6 Volts
Short Circuit Current (I sc) : 7.49 Amps

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm
Depth : 278 mm
Weight : 74 kg

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

Maximum Input DC Voltage : 1000 V


MPP Voltage range : 520 V - 800 V
Nominal AC Output Power, Pac : 50 kW
Nominal AC output Voltage : 400 Vac
Tare losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.

Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to
inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is
558MWH/year, with Specific Energy Yield of 1563 kWh/KWp/year and performance ratio of
79.62.03 %. The global solar radiation, diffuse solar radiation and mean hourly temperature data
from Meteonorm has been used for estimation of energy yield for the proposed power plant.
The energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 149.4 65.89 25.1 164 156.8 49.3 48.54 0.828
February 164.5 57.93 26.18 177.1 169.6 52.49 51.64 0.817
March 196.3 72.36 28.06 202.7 194.1 59.45 58.45 0.807
April 194.2 79.81 29.68 193.1 184.6 56.32 55.37 0.803
May 192.5 84.6 31.73 185.6 176.9 53.57 49.02 0.74
June 169.3 85.74 30.72 161.5 153.8 47.11 46.35 0.803
July 161.1 88.13 30.44 154.8 147.2 45.24 40.54 0.733
August 162.2 90.13 29.48 159.3 151.7 46.76 42.96 0.755
September 160.6 77.68 28.8 162.7 155.3 47.74 46.96 0.808
October 137.5 74.22 27.42 143.2 136.8 42.46 41.77 0.817
November 115.2 63.74 25.55 122.7 116.9 36.79 36.22 0.826
December 123.7 58.96 24.89 135.7 129.4 40.86 40.23 0.83
Year 1926.3 899.2 28.18 1962.5 1873.1 578.08 558.03 0.796

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Detailed Project Report of Solar Rooftop PV System at CSIR-CLRI, Chennai, Tamil Nadu

Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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DETAILED PROJECT REPORT FOR THE SOLAR ROOFTOP
PV SYSTEM AT CSIR-IIIM, J&K

North-East Institute of Science and Technology (IIIM),


Jammu & Kashmir.
Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

Contents
1. Executive Summary .............................................................................................................................. 2
2. Introduction ........................................................................................................................................... 3
3. All Information as per Form B .............................................................................................................. 5
3.1. Project Details [A] ........................................................................................................................ 5
3.2. Details of the plant site/location [B] ............................................................................................. 5
3.3. Operation and Maintenance Arrangements [C] ............................................................................ 7
3.4. Project Duration and Implementation Schedule[D] ...................................................................... 8
3.5. Monitoring Mechanism [E] ......................................................................................................... 11
3.6. Costing of Project[F]................................................................................................................... 11
4. Rooftop Solar Power Generation System Description ........................................................................ 12
5. System Description and Specification of the Components ................................................................. 15
6. Bill of material .................................................................................................................................... 20
7. Energy estimation ............................................................................................................................... 21
Annexure-I PV Module & MMS Maintenance Schedule ....................................................................... 22
Annexure-II Inverter Maintenance Schedule .......................................................................................... 22

List of Figures
Figure 1 Typical Solar PV System diagram................................................................................................ 14
Figure 2 Typical solar PV system components ........................................................................................... 15

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

1. Executive Summary
Sr. No Data Description
1 Project Promoter M/s CEL, Sahibabad, UP
2 Project capacity 396.58 KWp.
3 Project Location Canal Road, Jammu
a) Site Name Indian Institute of Integrative Medicine
(CSIR- IIIM)
b) State Jammu
e) District Jammu
f) Latitude 32.7301 N
g) Longitude 74.74851 E
h) Altitude 350 Mtr.
4 Connectivity
a) Nearest Railway Station Jammu Tavi Railway Station (6.7 km)
b) Nearest Airport Jammu Airport (9km)

5 Roof Details
a) Total Area Available (Unshaded) 4759.5 Sq. M
b) Nature of Roof Flat RCC roof

6 Substation Details
Nearest Grid Interconnection Point 415 V Bus bar at Existing LT Panel Room

7 Energy generated
a) Estimated Net Energy Generation per 599.3 MWh
annum
b) CUF 17.23%
c) Expected Life of Power Plant 25 years
8 Saving
a) Total Energy Saving 599.3 MWh
b) Total Saving (first year) Rs. 36.38 Lakh
c) Total Saving (25 years) Rs. 9.09 Cr

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

2. Introduction
This Detailed Project Report is prepared by M/s. Central Electronics. Ltd. (herein after CEL), Site
IV, Industrial Area, Sahibabad, UP, India (herein after CEL) on Detailed Project Report of 396.58
KWp DC Grid Interactive Rooftop Solar PV Power Project.
Government of India has been promoting new and renewable energy sources in a big way.
Jawaharlal Nehru National Solar Mission (JNNSM) launched by the Government of India vide
resolution No.30/69/20 13-14/NSM(Pt.) dated 7th January, 2015 by Pres ident of India for setting
up over 100 GW of Solar Power Plants by the year 2020 out of which 40 GW will be in the Rooftop
Solar Power Plant category.
The Ministry of New & Renewable Energy has directed expert agencies to implement the Grid
Connected Rooftop(GCRT) Power Projects in various CSIR Labs. M/S Central Electronics Limited
has been assigned with the implementation of GCRT power projects on the roofs of buildings
belonging to the CSIR Labs. CEL has been entrusted with the task of carrying out the followings
For the better readability the report has been divided to various sections in accordance with the
scope of work to be carried out for the final Project Report. The section being covered in the
report are broadly summarized below.

− Site Survey as per the standard format provided by MNRE.


− Study of the electrical load requirement and captive consumption of the establishment
at the site.
− Collection, verification and evaluation of solar radiation resource data and local
meteorological data and calculation of energy yield based on analysis of direct and
diffused solar radiation, seasonal and daily characteristic, load factor.
− Estimate the power generation potential depending on the site conditions.
− Preparation of preliminary Feasibility Report
− Layout of the grid connected solar plant as per MNRE specifications including all civil,
structural, electrical & all related works.
− Description of technical features and specifications of solar PV power plant
components including PV modules, inverter, transformer, cables, switchyard etc. of
power plant.
− The consultant shall provide cost estimates associated with the project Detailed
Project Report of 396.58 KWp Solar Rooftop Power Plant, Indian Institute of Integrative
Medicine, Jammu.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

o Basis of cost estimates


o Phasing of expenditure
o Possible costs and re venues for emission reduction certificates
o Remote Monitoring System, SCADA
o Operation and maintenance costs
o Escalation in O&M costs and its basis
o Taxes, duties and levies applied to equipment for solar power projects
o Financial analysis and economic analysis of the project.
− The consultant will prepare the DPR/ proposal for the End Customer as per specific
formats.
− The consultant shall have to prepare the complete Bid Documentation including
agreement, tendering, preparing draft agreement between the SPD (Solar Power
Developer) and End Customer. Bid Document for design, manufacture, Supply,
Erection, Testing & Commissioning, completion of solar
− power project and subsequent O&M of solar power project covering all technical
requirements for overall design, components, vendor/subcontractor selection,
performance assessment protocol, compliances of various rules and regulations
etc.
− Ministry of New & Renewable Energy has allocated & conveyed in principle
approval for setting up of grid connected Rooftop Solar power plant to CEL at
Indian Institute of Integrative Medicine, Jammu

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

3. All Information as per Form B


3.1. Project Details [A]

S. No Description Remark
1. Title of the Project SPV Grid tied Project at Indian
Institute of Integrative Medicine
(CSIR-IIIM)
2. Capacity of the plant (kWp) 396.58 KWp
3. Category of the Applicant/Project Proponent Government Organisation
4. Details of the Project Proponent
Name Mr. Ashwini Chopra
Designation Sup. Engineer
Mobile Number 9419797428
E-mail achopra@iiim.ac.in
5. Executive Summary of the Proposal Refer Section 1
6. Objective for implementing the Plant Self-consumption and diesel saving
(a) Sale of electricity to the distribution licensee at
feed-in tariff or competitively discovered rate
(b) Sale of electricity to the distribution licensee at
Average Pooled Price Cost (APPC) and
participation in REC Mechanism
(c) Sale of electricity to third party
(d) Self-consumption total or partial generation
(e) Diesel saving
(f) Combination of above (please mention)
(g) Any other, please specify
7. Any Other detail relevant for consideration of
support under the scheme by the evaluation
committee

3.2. Details of the plant site/location [B]

S No. Description Remarks


1 Is the plant located at the address mentioned in [A] 4 Same as [A]4
above; if No, Address of the location of the plant(s)
Name
H. No.
Street/Locality/Road
District
State
2 Is the beneficiary same as [B] 1 If No, Details of Project Same as [B]1
Beneficiary/ Organization
Head of the organization
Name of the contact person
Full address, phone, mobile and e-mail

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

3 Details of Proposed Power Plant


a) Proposed capacity of the SPV Power Plant (KWp) 396.58 KWp
b) Plant proposed at single site/multiple Single Site
c) Interconnection with the electricity network at Single Point
single point or multiple point
d) Availability of shadow free south facing rooftop/ Yes
land area for the power plant
e) Total loads to be energized by SPV Power 400 KW
Plant(KW)
f) Calculations and justification for the proposed As per industry practice the area
capacity (Please elaborate) required per KWp is around 12
sqm. The total available area at the
roof to install the plant is around
4795.5 SQM. So Total Proposed
Capacity of plant is 396.58 KWp.

g) Expected annual energy generation 599.3MWh/year


h) Space for housing the plant control systems and NA
battery bank (if any)

4 Details of electrical load where the plant is to be installed


(i) Total connected electrical load in KW/KVA (as 1940 KW
per electricity bill)
(ii) Applicable consumer category Commercial
(domestic/commercial/individual/ others)
(iii) Total electrical load to be met by the SPV 400 KW
power plant (kW)

5 Technology Description & System Design/Specification

1. Sketch/Line diagram of the complete SPV System with Attached


details (please attach drawing)
2. Capacity/ Power of each PV Module (Wp) 320 Wp
3. Number of modules and total array capacity (nos. & 1242 modules
kWp)
4. Solar cell technology and Module efficiency proposed Poly crystalline
to be used (mono-crystalline/ poly-crystalline/ thin Efficiency – 16.5 %
film/ any other)
5. Details of Tracking of PV Array, if proposed (single Fixed tilt installation
axis/ double axis tracking etc.)
6. PCU/inverter capacity with detailed specifications Delta RPI M50 A
(kVA) (Details of quality of output power, standards) Capacity – 50 Kw
7. Type of inverter (central/ string/ multi string/any String inverter
other), inverter efficiency Inverter efficiency – 98.4%
8. Number of PCU/inverters proposed to be used 8

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

9. DC Bus voltage 1000 V

10. Capacity of battery bank (Current, Voltage and AH), if Not Applicable
used, any
11. Type of battery proposed (lead acid tubular/ lithium Not Applicable
ion/ NaS/ any other)
12. Details of protections to be deployed on PV array and SPD, DC isolator, DC MCB, AC MCB,
AC output side Fuses, Overcurrent relays, Reverse
power relays.
13. Details of Metering, Indication, Data logging The data logger takes care
operation of data monitoring and regular
data logging of the SPV system.
14. Schematic diagram of the system including protecting DDE
interlocking devices, monitoring and data logging
points to be provided.
15. Details of Mounting system: Roof-top mounting system with
- Roof mounted system Fixed Tilt Hot dip galvanized
- Ground mounted system structure
16. Details of building to install the Electronics Control Existing ACDB Room
Panel and Battery Bank (if any)
(i) Whether any existing building is to be used as control
room
(ii) If a new building is to be constructed, area, estimated
cost, and etc. to be provided and time frame to
construct the building

3.3. Operation and Maintenance Arrangements [C]

S No. Description Remarks


− Details of Operation and Maintenance O&M schedule for the major equipment is
Arrangements tabulated in annexure I & II. Detail manual
and schedule to be prepared by the EPC
contractor. Some indicative standard practice
are as follows:
• Periodic cleaning of PV modules
• Preventive maintenance such as
cable lug condition check, junction
box fuse inspection etc.
• Safety guidelines and PPE shall be
available at site

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

− Arrangements for Generation Data • Online monitoring of plant


Collection through remote monitoring performance through WMS shall be
(applicable for SPV Power Plants having installed at each site individually.
more than 5 kWp capacity) • The generation & weather data will
be recorded and stored on portal and
able to access remotely.
• Generation data, cleaning records,
spare part inventory shall be
maintained in Daily/ Monthly solar
log book.

3.4. Project Duration and Implementation Schedule [D]

It is envisaged that the project will have the below mentioned phase of activities. These phases
are not mutually exclusive; to implement the project on fast track basis some degree of
overlapping is envisaged.

1. Project Development

2. Finalization of the Equipment and Contracts

3. Procurement and Construction

4. Plant Commissioning and performance testing

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

1. Project Development

In a power project, development of the project plays an important role. The below listed tasks
will be under project development:

1. Preparation of Detailed Project Report (DPR)


2. Participation in RFQ/submission of application with documents for registration
3. In Principle clearance from nodal agency
4. Financial closure

2. Finalization of the Equipment and Contracts

In the power plant PV modules and investors are the long lead items and the planning schedule
for the project implementation should provide adequate time period for the installation of these
equipment. The specifications for major equipment like the Modules, Invertors and design shall
be drawn up at an early stage of the project. Program of design information, from the equipment
suppliers, that satisfies the overall project schedule shall be drawn up.
Since, the project execution calls for closer coordination among the contractors, consultants and
the company, proper contract co-ordination and monitoring procedures shall be made to plan
and monitor the project progress.

3. Procurement and Construction

The procurement is an important function of the implementation of the project. Once the
purchase order is placed, the project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for the inter-package
engineering.
When the contract for the equipment are awarded, detailed program in the form of network are
tied up with the supplier to clearly indicate the owner's obligations and the supplier’s
responsibilities. And upon placement of the purchase order, the project team follows up regularly
to ensure smooth and timely execution of the contract and or obtaining technical information
for the inter-package engineering. The procurement activity includes review of drawings,
expediting, stage and final pre-delivery inspection, supervision of installation and commissioning.
To expedite supplies from the manufacturers, regular visits to the supplier's works will have to
be undertaken by the project engineers/consultants. The manufacturing program and quality
plans finalized at the time of award of contract. Regular reports shall be prepared indicating the
schedule variations, if any, their likely impact on the delivery schedule, and the recommendations
to meet with the schedules.
During construction, the erection and commissioning phase of all the contracts proceed
simultaneously. Adequate power and water shall be made available for the construction.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

4. Erection and Commissioning Phase

The commissioning phase in a project is one where design, manufacturing, erection and quality
assurance expertise are put to test. The commissioning team will be from manufacturer of the
equipment, consultant and the company. As discussed in the earlier section, staff identified to
operate the plant will be involved in the commissioning phase of the project itself.
When construction phase is complete, the check list designed to ensure that the plant has been
properly installed with appropriate safety measures. The commissioning team will follow the
operating instructions laid down by the plant and equipment manufacturer. The plant shall be
subjected to a performance test, after the successful completion of the performance test of the
plant; the plant will be taken over by the company.

All the statutory clearances will be obtained much before of the start of the project
commissioning.

The Project work plan chart is presented below: -

Work Sub-Work W1 W2 W3 W4 W5 W6 W7 W8
Design & Engineering
EPC contract finalization
Plant Construction

Mobilization
Vertical Post
installation
Racking installation
Module Installation
Electrical wiring
Inverter Installation
Installing Monitoring &
Control system
Testing &
Commissioning
Supply schedule(Site)
Module Mounting
structure
SPV Module
Cable & Electric
accessories
Inverter

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

3.5. Monitoring Mechanism [E]

The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed. RS485 Modbus
protocol oriented monitoring system will be implemented at the project site for real time data
logging. The mechanism of monitoring system for rooftop PV Plant are tabulated below: -

Own Mechanism (up to 5 KWp) NA


Remote Monitoring (for SPV power plants of 10kWp and To be arranged by the EPC contractor
above)

Following data from the system are logged and displayed.

• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

3.6. Costing of Project[F]

S No. Particulars Unit Cost (Rs. /Wp) Total Cost (Rs. In Lakh)

1 SPV Modules 24 95.2


2 Inverters 6 23.8
3 Module Mounting Structures 4 15.9
4 Electrical wires 4 15.9
5 Net Metering and other approval 2 7.9
6 BOS 4 15.9
7 Installation & Commissioning 4 15.9
8 O&M Cost for 5 Years 5 19.8
Total Cost 53 210.2

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

4. Rooftop Solar Power Generation System Description


A Photovoltaic system is a distributed power generation system that produces electrical power
by harnessing solar radiation and converting it into electricity. Solar power generation plants
come under the category of Renewable Energy sources as they do not involve the use of fossil
fuels such as coal or petroleum for power generation. Solar PV plants are classified broadly into
two major categories based on their location:

i. Ground-mounted Projects: In this case, the solar panels are mounted on mounting
structures that are set up on available land on respective mounting foundations. The entire
system including all the components like modules, inverters, cables, evacuation infrastructure
are based on ground only.

ii. Rooftop Projects: In this case the solar modules are mounted on the roof of an existing
building via appropriate mounting structures. The buildings may be of residential, commercial
or industrial nature. The roofs may be sloping sheet roofs or flat RCC roofs.

Solar irradiation varies throughout the day and since the power output of the system is directly
proportional to the level of irradiation on the module surface, the power output of the solar
array too varies throughout the day. A s a result, the inverter continuously matches the output
of the PV array with a reference power source to maximize the PV array output. Based on this
reference power source, PV systems are classified as:

i. Off-grid systems: In this case, the system comprises a battery bank that functions as the
reference power source as well as a storage mechanism which can supply power at night when
the Sun is not available.

ii. Grid-connected systems: In this case, the solar power system is coupled with the grid
which provides the reference power source and is also an unlimited storage option which can
supply electrical power whenever solar radiation is not available.

The main components of a Grid-connected Rooftop Solar Power Generation System are as
follows:
1. Solar Modules
2. Inverters
3. Module Mounting Structures
4. Balance of System (Cables, Junction boxes, Switchgear etc.)

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

A brief description of each of the components is presented below:


1. PV Modules – The PV modules are the devices that actually convert solar energy to electricity.
PV modules are made from PV cells, which are most commonly manufactured using silicon; other
materials used include cadmium telluride (CdTe), copper indium gallium selenide/sulfide (CIGS).
Generally, silicon-based solar cells provide higher efficiency (15% - 20%) but are relatively costly
to manufacture, whereas thin film cells are cheaper but less efficient (5% - 10%). Since different
types of PV modules have different characteristics (in terms of efficiency, cost, performance in
low irradiation levels, degradation rate), no single type is preferable for all projects. Good quality
PV modules generally have a useful life of 25 to 30 years. It is important to assess the quality of
PV modules for use in projects.

2. Inverter –The inverter converts the DC power produced by the PV modules into AC power.
The AC power is then either injected into the grid or consumed on-site. For grid-connected
rooftop solar applications, inverters come in standard sizes ranging from a few hundred watts to
hundreds of kilowatts, depending on system size. These inverters are usually string inverters,
which have smaller capacities (typically < 90 kW), as opposed to central inverters, which have
larger capacities (typically > 300 kW) and are generally used in MW-scale solar PV projects. There
are many different types of inverters in the market; selection of an inverter for a project depends
on a number of factors, including application, size, cost, function, usage, etc. Inverters also
perform energy monitoring functions. From the technology perspective, inverters have matured
to a large degree and opportunities of cost reduction through technology innovation are not
expected in the market. Top-of-the-line inverters offer efficiencies in the range of 97% - 99%.

3. Module Mounting Structure– The mounting structure, or racking system, is the support
structure that holds the PV panels. PV modules are generally mounted on support structures in
order to more efficiently capture solar insolation, increase generation, and have a stable
structural support. Mounting structures can be either fixed or tracking. Fixed tilt mounting
systems are simpler, low-maintenance and cheaper than tracking systems. Due to these reasons,
fixed tilt mounting structures are the norm in India. Mounting structure designs are highly
specific to the site, and over time have seen improvement in durability and reduction in costs.
Cost reduction is mostly achieved through designs that use less material (mostly steel or
aluminium). Mounting structures for rooftop solar PV installations also require compliance with
regulations or guidelines associated with the structural aspects of the roof, such as load-bearing
capacity, wind loading, etc.

4. Balance of System – Balance of system (BoS) consist of cables, switchboards, junction


boxes, meters, etc. Electricity meters record the amount of electricity consume d and/or
produced (in kWh and kVAh) by a customer within a premises. In addition to the metering of the
net energy consumption/production of a grid-connected rooftop solar PV system, most
regulations in India on metering also stipulate the location of a n energy meter for measuring the
generation of the PV array.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

A general schematic of the working of a Grid-Connected Rooftop PV System is shown below:

Figure 1 Typical Solar PV System diagram

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

5. System Description and Specification of the Components


Any solar PV power project consists of following major components

• Solar PV modules
• String Inverters
• Transformers
• Balance of Plant

Figure 2 Typical solar PV system components

Solar PV modules Technology Considerations


CEL have compared the solar module technologies and recommended the crystalline technology
based on the Indian environment considerations, efficiency considerations, and Indian market
share. The Typical PV module considered with the following specification is used for the purpose
of preparing site layout and energy yield estimation.

PV Module type : Multi crystalline


Make : CEL
Model : PM320

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

Physical Dimensions
Length : 1965 mm
Width : 990 mm
Thickness : 42 mm
Weight : 25 kg

Electrical Parameter at STC : 1,000 W/m² ,1.5 A.M. and 25°C


Rated Power (Pmax) : 320 Wp
Rated Voltage (Vmp) : 36.8 Volts
Rated Current (Imp) : 8.7 Amps
Open Circuit Voltage (V oc) : 45.3 Volts
Short Circuit Current (I sc) : 9.42 Amps
Temp Coefficient of Pm ax : - 0.4383% /K
Module Efficiency : 16.5 %

Solar Modules are rated under industrial Standard Test Conditions (STC) of solar irradiance of
1,000 W/m² with zero angle of incidence, solar spectrum of 1.5 air mass and 25°C cell
temperature and also at Nominal Operating Cell Temperature (NOCT) when operating under
800 W/m2 irradiance, 20°C ambient temperature and wind speed of 1 m/s. Solar modules, when
operating in the field typically operate even at higher temperature. This higher operating
temperature of module results in the losses due to the temperature coefficient. For this module
the temperature coefficient is - 0.4383% /K rise in temperature.

String Inverters (PCU)

Technology Considerations
CEL have compared the inverter connection technologies and recommend ed string inverters
based on the site layout and Indian market share. The typical PCU considered with the following
specification for the purpose e of preparing site layout and energy yield estimation.

Make : Delta
Inverter Cabinet Dimensions
Height : 740 mm
Width : 612 mm
Depth : 278 mm
Weight : 74 kg
Maximum Input DC Voltage : 1000 V
MPP Voltage range : 520 V - 800 V

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

Nominal AC Output Power, Pac : 50 kW


Nominal AC output Voltage : 400 Vac
Total losses (night consumption) : 2W
Max AC Current : 73 A
Output Grid Frequency : 50 Hz
Max Efficiency : 98.6 %
European efficiency : 98.4 %

Junction Box
Junction boxes will be made of thick (suitable thickness) sheet steel, suitable for outdoor application.
This will be suitable for mounting on structure steel. Terminal block of 16A rating with disconnecting
links will be present inside the junction boxes. Earthing connection mounts will be provided in
the junction boxes.
The junction Boxes will have suitable arrangement for the followings (typical): -
Ø Combine groups of modules into independent charging sub-arrays that will be wired
into the controller.
Ø Provide arrangement for disconnection of each of the groups.
Ø Provide a test point for each sub-group for quick fault location.
Ø Provide group array isolation.
Ø The current carrying ratings of the junction Boxes will be suitable with adequate safety
factor to inter connect the Solar PV array.

AC Distribution Box
The AC Distribution Box (ACDB) is provided between the PCU and the main LT distribution panel
to provide suitable protection, insulation and change-over between the load and the power
output of the PCU. Standard industrial make ACDB will be used at the project site. Typically, the
ACDB is manufactured from powder-coated metal enclosures and houses the suitably rated MCB,
Isolators and manual change-over switches. The ACDB consists of a distribution feeder that is
used to cater to the existing loads of the facility with solar generated electrical power.

Cabling
Cables used are extremely robust and resist high mechanical load and abrasion. Good
temperature resistance and excellent weatherproofing characteristics also provide long service
life to the cables used. The connectors used have high current capacity and are easy to use.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

LT Cables
1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between the solar modules, strings to junction boxes and from junction boxes to
inverters. The LT cables will be laid using GI galvanized cable trays of adequate strength. The
cable will be terminated using Al Lugs of adequate cross section area.

1.1kV grade, Al conductor XLPE cables of suitable diameter will be used as the power cable for
connection between inverters and the step-up transform. The LT cables will be laid using
underground cable trenches to reduce transmission and interference loss. The cable will be
terminated using Al Lugs of adequate cross sectional area.

Control Cables
1.1kV Grade, Cu. Conductor, XLPE Armoured Cables will be used for all control cables required
for the Solar Power Plant. These cables will be laid on structural supports and using Galvanized
Cable trays of adequate strength. The cable will be terminated using Cu Lugs of adequate cross
section area.
The terminal end of cables and wires will be fitted with good quality letter and number ferrules
of proper sizes so that the cables can be identified easily.

Earthing System
The earthing for the power plant equipment shall be made as per provisions of IS: 3043. Earthing
system should be made with GI pipe, 3-meter-long & 40 mm diameter including accessories and
providing masonry enclosure with cast iron cover plate having locking arrangement, watering
pipe using charcoal or coke and salt as per IS standards. Necessary provision shall be made for
bolted isolating joints of each earthing pit for periodic checking of earth resistance.
The complete earthing system shall be mechanically and electrically connected to provide
independent return to earth.
In compliance to Rule 33 and 61 of Indian electricity act 1956 (as amended up to date), all non-
current carrying metal parts should be earthed with two separate and distinct earth continuity
conductors to efficient earth electrodes.

Protective Relays
The SPV system and the associated power evacuation system shall be protected as per Indian
Standards. Over Current Relays, Reverse Power Relays and Earth Fault Relays are the minimum
requirements.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

Energy Meter
For the purpose of energy accounting, Solar based generation projects will have to provide ABT
compliant meters at the interface points. Interfacing metering shall confirm to the Central
Electricity Authority (Installation and Operation of Meters) Regulations, 2006.

Fire Fighting Instruments


The fire-fighting systems design shall confirm to TAC/NFPA norms. The type of fire protection
systems for complete plant shall be including portable fire extinguishers and wheel/trolley
mounted fire extinguishers.
Adequate number of portable fire extinguishers of dry chemical powder and carbon dioxide type
shall be provided at suitable locations in different buildings. Wheel/trolley mounted mechanical
foam type fire extinguishers of 50 liters capacity, confirming IS: 1 3386 are proposed to be
provided for protection of transformers in all LT & HT switchgear buildings.

Data Logger
The data logger takes care of data monitoring and regular data logging of the SPV system. The
data logger also allows user to perform monitoring and logging of multiple connected PCU’s.
Once the system is configured real time data can be obtained and displayed.
Following data from the system are logged and displayed.
• Solar radiation
• Ambient temperature
• Module temperature
• DC voltage
• DC current
• DC power
• Grid voltage, frequency, current
• Inverter voltage, frequency, current
• Energy exported

Mounting Structure Foundation


Mounting structure foundation is designed to fix the structure in such a way that the roof will
sustain the weight of the total module placed on single array and wind velocity up to 150 km/hr.
The roof condition has to be taken care of during design and construction of foundation. The EPC
contractor is responsible for supply and execution of module foundation as per international
practice.

Signboard
The Signboard will contain the brief of the Power Plant. The Signboard will be made of steel
coated aluminium letters with p roper illumination arrangement. The design & size of the
signboard shall be befitting with control room and matter.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

6. Bill of material
The Supply scope of the EPC contractor shall be deemed to include all such items which although
are not specifically mentioned in the below table but are needed to make the system complete
in all respects for its safe, reliable, efficient and trouble free operation and the same shall be
furnished and erected unless otherwise specifically excluded. The equipment and material for
Rooftop Grid Interactive Solar Photovoltaic Power Plant with associate system (typical) shall
include, but not limited to the following:

Item Details Unit


PV Modules Nos.
Module Mounting Structures Set
Array Junction Boxes Lot.
Solar DC Cable Lot.
Connection accessories – lugs, ferrules, glands etc. Lot.
AC Cable of appropriate sizes Lot.
Power Conditioning Units/ Inverters Nos.
WMS and data logger Set.
Lightning Arresters of suitable ratings Lot.
Control and power cables Lot.
Surge Protection devices and fuse Lot.
Earth cables, flats and earthing pits Lot.
Equipment and Control cum office Building Lot.
Rubber Mats for specific kV ratings Lot.
CO2 Extinguisher Lot.
Sand Buckets Lot.
Fire – fighting automation and signboards in buildings Lot.
Metering Equipment (Meters, and associated CT and PT‟s) Lot.
Protection Equipment Lot.
Module cleaning system Lot.
Danger plates etc. Lot.
Balance equipment other than specified above Lot.

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

7. Energy estimation
PVSYST software provides possibility of complex simulation input and output parameters of PV
plant and is also commercially to calculate the total production of electricity. The report deals
with energy yield forecast of Solar photovoltaic plant as follows:
As per the PVsyst simulation results, the estimated energy generation for the first year is 599.3
MWh/year, with Specific Energy Yield of 1508 kWh/KWp/year and performance ratio of 800.37
%. The global solar radiation, diffuse solar radiation and mean hourly temperature data from
Meteonorm has been used for estimation of energy yield for the proposed power plant. The
energy yield estimation as per PVsyst Report is tabulated below:

Month Glob Hor Diff Hor T Amb GlobInc Glob Eff E Array E_Grid PR
kWh/m² kWh/m² °C kWh/m² kWh/m² MWh MWh
January 83.6 42.9 11.17 113.7 108 40.39 39.84 0.881
February 93.1 49.2 15.15 115.7 109.9 40.09 36.88 0.802
March 141.2 70.5 20.76 161.9 153.5 54.37 53.56 0.832
April 161 81.3 26.39 167.9 159 54.72 53.84 0.807
May 193.3 94.2 32 188.8 178.6 59.77 58.76 0.783
June 187.8 105.1 31.76 178.7 168.9 57.12 56.18 0.791
July 170.9 99.1 30.71 164.4 155.4 53.05 52.19 0.799
August 157.4 92.9 30.12 158.4 149.9 51.35 50.53 0.803
September 161.3 72.3 28.04 180.6 171.5 58.79 57.84 0.806
October 141.1 54.2 24.85 177.2 168.8 58.41 51.61 0.733
November 106.2 37.3 18.21 151.2 144.2 51.66 47.33 0.788
December 82.2 39.4 13.13 117.5 111.8 41.28 40.7 0.871
Year 1679.1 838.4 23.56 1876 1779.5 621 599.27 0.804

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Detailed Project Report of Solar Rooftop PV System at Indian Institute of Integrative
Medicine (CSIR-IIIM), Jammu

Annexure-I PV Module & MMS Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Check the cleanness of the Module – As per requirement

2 Check for the module against cracks and glass broken – As per requirement

3 Check the tightness of Connecter and Cable connection – As per requirement

4 Check the Water tightness of terminal

5 Check if any Water penetration in to the interior of the module

6 Check the tightness of the Grounding connection/negative earthing

7 Check the Healthiness of the Fuses and Circuit Breaker

Module mounting Bolts and nuts tightening, visual checks for rust, MMS visual
8
check for rust and paint
D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

Annexure-II Inverter Maintenance Schedule

Sr. No Check Points D W M Q Y

1 Checking the Fans are Operating

2 Checking the Heating

3 Cleaning the Fan

Checking the Interior of the Connection cabinet for


4
Dirt/Dust.
5 Checking the Screw connections of the Power Cable.

6 Checking the Screw Connections of all Assemblies.

D=Daily W=Weekly M=Monthly Q=Quarterly Y-Yearly

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