Industrial Solar Rooftop plant for PTC Industries

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Overview

Jakson successfully installed and commissioned a 700 KW rooftop solar power plant at a metal castings foundry owned by PTC Industries in Lucknow. Jakson provided turnkey solar EPC services for this plant that included design, engineering, supply, erection, construction, testing & commissioning, and related civil work. The project was executed under Solar Energy Corporation of India (SECI) Scheme for Rooftop Grid Connected Solar Power.

The plant will generate upto 2800 units of green energy every day for captive consumption. It was also enabled with net-metering facility to sell off excess electricity to power utilities.

Client

PTC Industries Limited earlier known as Precision Tools & Castings Private Limited is one of India’s oldest casting foundries established in the year 1963. It operates 2 state-of-the-art foundries in India meeting requirements for a wide range of industries like Valves and Pumps, Power Generation, Pulverizing and Crushing, Mining and Earth Moving, Rail and River Transport, amongst others.

Business need

Foundry is a high energy intensive industry with major consumption of electrical energy occurring during the melting process of metals during casting. Energy management therefore is of prime importance, and directly impacts the firm’s operating costs.

With the objective of generating its own electricity and make best use of its available rooftop infrastructure, PTC Industries, Lucknow planned to install a 700 KW solar rooftop power plant on the roof of its manufacturing facility.

Rooftop power plants have emerged as a viable source of power that can enable industrial units to substantially reduce their ever increasing electricity costs. When combined with Net Metering facility, these rooftop solar plants can result in substantial savings in electricity costs as well as significantly reduce their carbon emissions.

Considering all of the above, the client wanted to install a rooftop solar power plant for captive consumption at one of its foundries in Lucknow to reduce the high electricity and operational costs of its plant.

Challenges

  • Tilted roof – The roof of the plant was tilted at a 15 degree slope which created difficulties for workers to for installation of rooftop modules
  • The roofing was old and consisted of aluminium sheets which had limitation in sustaining heavy loads
  • The roofs allowed opportunity for limited piercing to install MMS structures

 

Solution

To provide a safe working condition for workers, temporary walking pathways were created on the tin roof structure. All workers were made to wear proper safety equipment to ensure that no life was in danger during the execution of the plant.  In addition, temporary lifts and cranes were at site to ensure faster execution.

To reduce the load on the tin roof, the structure of the installation was designed in an innovative manner to divert the load on the beams and trusses of the plant.

A total of 2360 high-efficiency PV modules of 310 Wp each were installed atop the foundry roof to install the requisite capacity of 700 KW. The entire installation was carried out using non-penetrative GI and aluminium module mounting structures. The plant is enabled with remote monitoring facility as well as net metering facility to sell off the excess electricity generated to power utilities, helping the foundry to reduce their operational costs.

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