Solar PV Project Implementation

How to stay on track & avoid pitfalls?

Typical Timeline

750 MW of Solar PV Projects under Phase II Batch I of National Solar Mission would
get 13 months from PPA signing to commission the Power Plants.

Identification of Land Parcels Preparation of DPR Panic

Techno Commercial Evaluation Project Financial & Technical Assessment Zone
Negotiation, Mutation & Registration In Principle Sanction & Disbursement

Technology Finalization Basic & Detailed Engineering

Invitation of Quotations & Meetings Equipment Procurement
Negotiation & Finalization Construction & Commissioning

Land Acquisition
EPC Contractor /
Equipment Selection
Financial Closure
Plant Construction (EPC)
Buffer
1 2 3 4 5 6 7 8 9 10 11 12 13
Months

Assuming a 10 MW Project taking 4 months in construction and 1 month for planning

EPC – Meaning
Engineering
There are approximately 110
drawings and design documents
including Electrical DC, Electrical
AC and Structural Engineering
which need to be prepared to start
execution.
Procurement
The Request for Proposals are
floated for approximately 25
different packages including –
Modules, Inverters, Mounting
Structures, Cables, Transformers,
HT & LT Panels, Electrical, Civil &
Transmission Line Contractors etc.
Negotiation and Finalization of
vendors is done based on Techno
Commercial reasons.
Construction
The Contractors appointed execute
the plant in a phased manner often
using specialized machinery
including ramming & auguring
machines, hydras, loaders, cranes,
mixers, AJAX, tractors etc.
Typically, multiple gangs of labor
are used taking the total number
from 50 to 300 depending on size
of the plant and execution time.
EPC – Concerns for Delay

Engineering Procurement Construction

Engineering of a Solar Power Plant is based on various technical data including Site Contour Survey, Soil Load Bearing
Capacity, Module & Inverter Specifications etc. Further, choice of technology plays an important role in Plant
Engineering.
The reasons for delay during Engineering phase are
• Delay in conducting the preliminary surveys & studies required for Engineering. Typically these studies cost less
than 0.1% of the project cost and should be undertaken as soon as site is finalized
• Improper or incomplete assessment of all the Technical Parameters like fault level of the substation where the solar
power is to be evacuated
• Repeated Change in Specifications of Equipment, possibly because of Procurement Indecision – A change of panel
wattage from 250 Wp to 300 Wp would alter at least 50 drawings including all layouts & structure drawings.
• Carrying out different aspects of engineering in isolation. For eg. The Layout for Trenches if designed without due
concerns for roads & drainage.
EPC – Concerns for Delay

Engineering Procurement Construction

Delays in delivery is the most common reason for delay of solar project, particularly because of delay in procurement of
Long Lead equipment:
Transformers: Lead time 6 – 10 weeks
Solar Power Plants typically use Double Primary Winding, low loss transformers which are made to order for projects.
The typical lead time is 6 – 10 weeks based on the make and spec of transformer. It is often not possible to squeeze
the timelines further as the raw material procurement for transformer assembly takes approximately 3 weeks to reach
the manufacturing plant. Further, drawing & inspection approval add to the problems.
CT, PT & Meters: Lead time 8 weeks
This equipment typically installed at the Plant Switchyard can be procured only from particular empanelled suppliers for
that state. Although, manufacturing time of these equipment is not long, however, the testing of these equipment takes
place in presence of respective discom representative’s presence and equipment is issued in the name of the project.
EPC – Concerns for Delay

Engineering Procurement Construction

HT Panels: Lead Time – 8 weeks

HT Panels are custom made according to the Voltage & Current ratings and design of the particular project. The HT
Panels contain protection equipment for the power plant at high voltage levels. The relays required to construct such a
panel are often not readily available and leads to delays.
Solar Modules: Lead Time – 6 – 12 weeks
The Solar Modules in most Indian Solar Projects are imported. Even when made with Domestic Cells, these cells have
a long lead time. On placement of order, the schedule for production is frozen which then follows the shipping period of
14 – 21 days depending on vessel availability. Further transportation from port to site would take another 7 days.
Inverters: Lead Time – 8 - 12 weeks
Inverters till last year were mostly imported. However, with multiple inverter suppliers setting up assembly plants in
India, the lead time is reduced. In critical situations, it is not uncommon to airlift inverters meant to be imported.
EPC – Concerns for Delay

Engineering Procurement Construction

Mounting Structures: 4 – 6 Weeks

Typically hot dipped galvanized iron (GI) is used for rafters and legs of module mounting structures, while cold rolled
pre galvanized sheets are made to desired sections and shapes for purlins on which the modules are fixed. There are
limited manufacturers of cold rolled steel like Jindal, Tata etc and though, there are multiple suppliers of hot dipped GI,
however, the zinc bath is often not deep enough leading to defects. Although, the lead time of Mounting Structures is
not high. However, it is the most important as Mounting Structures are the first equipment to be installed on site.
Cables: 4 – 6 Weeks
Cables are classified into 2 categories: DC Cables from module upto inverters and AC Cables from inverter upto
transmission line. Although, there are very reputed suppliers of both cables available in India, the Copper Cables are
often imported. When manufactured in India, the lead time can be as less as 4 weeks, while when imported it may
increase upto 6 – 8 weeks.
EPC – Concerns for Delay

Engineering Procurement Construction

Key Suppliers
Modules Inverters Transformers DC Cables HT Panel
Canadian Solar SMA Crompton & Greaves Lapp ABB
Yingli Solar ABB & PowerOne Voltamp Leoni Areva
REC Solar Schneider Emco Seichem Scheider
Trina Solar Bonfiglioli Raychem RPG Polycab Siemens
Jinko Solar AEG ABB KEI
Renesola Hitachi Areva Mounting Structures
Chint Solar Toshiba Schneider AC Cables Tata Bluescope
Hanwha GE Polycab Pennar Steel
Havells
KEI
EPC – Concerns for Delay

Engineering Procurement Construction

The reasons for delay during Construction phase are

Inadequate Labor and/or machinery
Labor and machinery planning typically needs to be carried at least 2 – 4 weeks in advance in accordance with the
requirements of the implementation schedule. Skilled labor in the Solar Sector are easy to come across in states of
Rajasthan and Gujarat, while they need to be supervised closely in others.
Right of Way
The transmission line when being erected, encounters various problems of crossing private lands where the owners
might not be cooperative and demand unreasonable compensation for transmission poles / towers falling in their land.
Transmission Line for Solar Projects is covered under Activities for Public Good according to Section 63 E of the
Electricity Act and hence, the work may be carried out with Administrative Support once permissions are taken.
However, considering that the Project has a life of 25 years, it is best to establish good relations with the land owners.
Local Issues
EPC – Concerns for Delay

Engineering Procurement Construction

Local Issues
Solar Power Plants are typically constructed away from cities. It is typical to encounter demands of employment and
usage of locally available machinery and labor (mostly unskilled) and sometimes even sand and cement during
construction and O&M. It is advisable to take local population in confidence in the beginning of construction. For large
power plants, it would help if developmental activities like construction of a temple, school or housing is also done.
Civil Works
Civil Works wherever done require minimum curing time, else the quality of the civil structure will deteriorate overtime.
There is a shift towards Pre Fab structures to avoid this nowadays.
Cable & Allied Items Quantity Mismatch
It is not uncommon to encounter quantity mismatch of cables among other equipment during construction because of
undercalculation of lengths for bending radius, terminations and in some cases even theft on site. It is best to order a
contingency of at least 5 – 10% extra.
Permits – The Little Known Devil
Pre Construction
• State Nodal Agency Registration
• Power Purchase Agreement
• Acquisition, Mutation and
Registration of Land Parcels
• Permission for Evacuation of
Power to a Substation
During Construction
• Change of Land Use to Industrial
• Consent to Establish from
Pollution Control Board
• MNRE Exemption Certificates for
Customs & Excise Duty
• Chief Electrical Inspector Approval
for Drawings
• CT / PT & Meters Inspection
• Transmission Line Permits
• Labor Licenses
Commissioning
• Chief Electrical Inspector Approval
of Installation
• Consent to Operate from Pollution
Control Board
• Permission for Connecting Plant to
Substation
• Commissioning Certificate
Permits – Concerns for Delay
Pre Construction
• State Nodal Agency Registration
• Power Purchase Agreement
• Acquisition, Mutation and
Registration of Land Parcels
• Permission for Evacuation of
Power to a Substation
• Land Acquisition & Final
Negotiation can take a long time
particularly for large solar power
plants covering 100’s of acres.
• Permission for Evacuation is
typically given after Load Flow
Studies which can take upto 4 - 6
weeks
During Construction
• Change of Land Use to Industrial
• Consent to Establish from
Pollution Control Board
• MNRE Exemption Certificates for
Customs & Excise Duty
• Chief Electrical Inspector Approval
for Drawings
• Change of Land Use can take
• CT / PT & Meters Inspection
considerable time, often many
• Transmission Line Permits
months, as they require the
• Labor Licenses
consent of Collector or SDM.
• Although, the process of MNRE
Exemptions is very well defined
and transparent. However, it
requires accurate & correct
calculation of BoM, else any
change would lead to delays.
Commissioning
• Chief Electrical Inspector Approval
of Installation
• Consent to Operate from Pollution
Control Board
• Permission for Connecting Plant to
Substation
• Commissioning Certificate
• CEI and Commissioning Teams are
mostly cooperative. However,
when running against timeline, and
particularly when other plants in
the vicinity are also scheduled for
commissioning, it is important to
avoid scheduling conflicts.
Recommendations
Delay of 1 day in
commissioning of a 10 MW
Plant leads to a loss of
Rs. 6.5 Lacs in terms of
Loss of Generation and
Interest During Construction
in addition to the statutory
penalties in case of
exceeding timelines.
• Carry on the Technical Assessment Studies – Soil Testing, Contour
Survey, Load Flow Analysis – which comprise less than 0.1% of the cost
of project as soon as site is finalized.
• Do not wait for the ideal proposal – land, EPC or Financing – as settling
for the best proposal available would enable project completion in time.
The risk of delay far outweighs the extra cost.
• Manage Lead Times of the critical equipment
• Unlike other infrastructure projects, Solar Power Projects are built over a
small time of 4 – 8 months. Adopt a pro active approach to any problem.
• Understand and respect the Permits and Clearances required. Although, a
small part of the project cost, they can handicap execution beyond repair if
due attention is not given.
Pre Warned is Pre Armed...
About Gensol Consultants Pvt Ltd

Gensol, an ISO 9001:2008 certified company is a pioneer in

Solar Power Advisory and Project Execution. Gensol is an
advisor to 800MW+ commissioned or under construction
Solar PV Projects and has a cumulative portfolio of more
than 1 MW of rooftop solar power plants under execution.

360o Clean Energy Solutions:

• Solar Advisory & Project Execution

• Carbon Advisory & Trading
• Renewable Energy Certificate Advisory & Trading
• Power Trading
About Gensol Consultants Pvt Ltd

Few Facts:
• 30+ Trained Team - all Graduates and Post Graduates in
Energy and Environment
• 800 MW+ Solar Power Projects under advisory
• 1 MW+ Solar Rooftop Projects under Execution
• Recipient of multiple awards including BusinessWorld Hottest
Young Entrepreneur and Economic Times Power of Ideas.

Quoted In:
Business Dailies: Business Standard | Economic Times Business
Magazines: Business India | Forbes India
Industry Journals: Power Line | Energetica | EQ International

Empanelled With:
Ministry of New & Renewable Energy
ANERT, Kerala (10,000 solar rooftops program)
Central Bank of India, PTC Project Financial Services,
L&T Infra Finance & Other Banks
Solar Advisory & EPC Services

Owner’s Engineer:
As Owner's Engineer, we guide our clients or investors through the complete process of project feasibility, financial closure, bid process
management, vendor finalization and supervision of project execution up till successful project commissioning which meets our strict
quality criteria.

Lender’s Engineer:
Being consultants to some of the leading lending institutions in the country, we assess the key parameters impacting the returns from the
project like generation, cost and conditions of the EPC Contract, preparedness of Project Developer for execution etc.

Detailed Engineering and Vetting of Drawings:

Gensol Solar Division is staffed with experienced Electrical, Electronics, Mechanical and Civil Engineers who undertake detailed
engineering of Solar PV Power plants on behalf of EPC Contractors and vetting of drawings for Project Developers and investors.

Permits & Clearances:

It takes more than 32 permits and clearances from Nodal Agencies, District Authorities, Distribution and Transmission Companies etc.
Gensol has an experienced liasoning team well aware of process and people to acquire these permits in time and in sequence.

Detailed Project Report:

A Detailed Project Report is one of the most important documents to assess the feasibility of project and to get financial closure. Gensol
with its sector expertise and established standing in the renewable energy consultancy not only gives the most exhaustive analysis of the
project but also enjoys the confidence of industries, investors and banks alike.

Solar EPC Services

Gensol, being a channel partner of Ministry of New and Renewable Energy (MNRE) has attained amongst the highest
allocation of subsidies for the Solar Rooftop Projects on account of its superior engineering, standardized procurement and
quick execution. Gensol has executed projects in the range of 1 kW powerpacks to 400 kW single rooftop power plants.
Experience Snapshot

Gensol is among the leading consultants to Project

Developers, Financial Institutions and Investors. Total
portfolio of Solar Power Projects commissioned or under
construction under advisory at Gensol is more than 800 MW.
Owner’s Engineer: Lender’s Engineer:
• 33 MW – Sterling & Wilson, Rajasthan • 130 MW – Welspun MP Energy, Madhya Pradesh
• 25 MW – Alex Astral Solar Power Ltd., Gujarat • 50 MW – Welspun Energy Ltd, Rajasthan
• 20 MW – Essel Infraprojects, Maharashtra • 25 MW – Sun Edison, Gujarat
• 20 MW – SolaireDirect, Punjab • 20 MW – PLG Power, Gujarat
• 17 MW – Sunrays Power Solutions, Rajasthan • 15 MW – MI Mysolar 24, Gujarat
• 15 MW – NALCO, Orissa • 15 MW – Dreisatz Mysolar 24, Gujarat
• 10 MW – Ghodawat Energy, Rajasthan • 10 MW – Greeninfra Solar, Gujarat
• 6.5 MW – Haryana Power Generation Corporation Ltd, • 10 MW – Millenium Synergy, Gujarat
Haryana Govt Enterprise • 6.5 MW – Sun Group, Gujarat
• 5 MW – Alex Spectrum Radiation Pvt Ltd, Rajasthan • 6 MW – Indiabulls Power, UP & Maharashtra
• 3 MW – Par Solar, Rajasthan • 5 MW – ESP Urja, Gujarat
• 1.5 MW – Agarwal Infratech Ltd, Gujarat Feasibility Analysis & DPR:
• 350 kW – Mapro Foods Pvt Ltd, Maharashtra • 20 MW – Sai Sudhir Energy, Andhra Pradesh
Detailed Designing & Design Vetting • 10 MW – Sai Sudhir Energy, Karnataka
• 20 MW – Client Confidential, Gujarat • 5 MW – Chemtrol Industries, Rajasthan
• 12 MW – Lanco Solar, Andhra Pradesh • 2 MW – Shri Bhagirathi Textiles Ltd, Maharashtra
• 8.5 MW – Jain Irrigation, Maharashtra • 15 MW – Boyance Infrastructure, Rajasthan
• 5 MW – ABB Ltd, Gujarat • 5 MW – Sattva Salarpuria Group, Karnataka
• 1 MW – L&T ECC Division, Rajasthan • 1 MW – NIT Hamirpur, Himachal Pradhesh
Experience Snapshot

Gensol is among the forefront of Solar Rooftop execution

with more than 1 MW as its clientele ranging from 1 kW
power packs upto 400 kW single rooftop power plants.
Advisory:
• 163 MW Grid Connected Gujarat
• 130 MW Grid Connected Madhya Pradesh
• 129 MW Grid Connected Rajasthan
• 55 MW Grid Connected Punjab
• 35 MW Grid Connected Maharashtra
• 18 MW Grid Connected Karnataka
• 15 MW Grid Connected Odisha
• 6.5 MW Grid Connected Haryana
• 2 MW Grid Connected Uttarakhand
• 2 MW Grid Connected Uttar Pradesh
• 1 MW Grid Connected Himachal Pradesh
Execution:
• 300 kW Rooftop Grid tied Andhra Pradesh
• 100 kW Rooftop Grid tied Karnataka
• 92 kW Grid Tied & Off Grid Gujarat
• Empanelled with ANERT, Kerala for 10,000 Rooftops
Solar Program
Experience Snapshot

Gensol Consultants is a member of the Power Exchange for

trading of Power and RECs and also has portfolio in excess
of 10 million carbon credits across 16 states in India.

Power Trading Clients: CDM Clients: REC Based Projects:

• Maize Products • Hotel Golden Emerald
• Yes Fashions • Sree Minerals Pvt Ltd
• Dishman Pharma • BVSR Energy Systems
• Jay Chemical Industries Ltd • Singrun Realities
• Aarvee Denims and exports Ltd. • RCM Fashion Suiting Ltd
• Texmo Industries • NecLife Science Ltd.
• Heavy Metals • Balaji Waffers Ltd
• Brigade group • Texmo Ltd
• B K Developers • Pothys
• Green Ply • Zaveri & Co. Exports
• Time Technoplast • Sanghvi Forging Eng. Ltd
• Paramount Paper Steel Cast Ltd. • Ispat Udyog.
• Madhu Silica Pvt Ltd • Kishco Ltd
• Jindal Steels.
• P & R Engineering Services Ltd.
• P & R Engineering Services Ltd.
• Sayaji Industries Ltd.
• Baghauli Sugars
• Santlal Industries Ltd
• Vishal Paper Industries Pvt Ltd
• Shree Bhageshwari Papers Ltd
• Daulat Rice & General Mill
• Ganga Pulp & Papers Ltd.
• RP Basmati rice Ltd.
Gensol Engineering Pvt Ltd | Gensol Consultants Pvt Ltd

Corporate Office
108, Pinnacle Business Park
Opp Royal Arcade, Prahladnagar
Ahmedabad, Gujarat
India - 380015

Email: solar@gensol.in
Website: www.gensol.in
Phone: +91 79 40068235
Fax: +91 79 40068239
Twitter: gensol_tweets

Gensol is one of the leading consultants and system integrators for Solar Power Plants. We boast of a portfolio of over 800
MW of Solar Photovoltaic Plants. Gensol is also a channel partner to Ministry of New & Renewable Energy and installs kW
scale Solar Rooftop systems on a turnkey basis with more than 1 MW of cumulative installations across the country.

The information contained herein is of a general nature and is not intended to address the circumstances of any particular
individual or entity. Although we endeavor to provide accurate and timely information, there can be no guarantee that such
information is accurate as of the date it is received or that it will continue to be accurate in the future. No one should act on
such information without appropriate professional advice after a thorough examination of the particular situation.