Solar Power Solution for K.H. Shoes Pvt Ltd

Solar Power Solution for K.H. Shoes Pvt Ltd

September 2013


Photovoltaic:The physical effect of direct Conversion of light (sunlight) to electrical energy.

PV Cell:The smallest photovoltaic (PV) element that generates electricity from light.

PV Module:A collection of interconnected PV cells, encapsulated between protective materials such as glass and back sheet (Poly Vinyl Fluoride) or glass and glass, and mounted in an aluminum frame. This is a hermetically sealed unit.

Array:Several strings of modules with the same orientation and tilt angle, located together.

Inverter:An electronic device that converts direct current electricity into alternating current electricity suitable for feeding directly to the electrical grid or to normal AC loads.

Insolation:It is a measure of solar radiation energy received on a given surface area in a given time. It is commonly expressed as average irradiance in watts per square meter (W/m²) or kilowatt-hours per square meter per day (kWh/ (m²day)) (or hours/day).

Mounting Structure:Device used to hold modules in place, at desired angle & direction.

Power Evacuation:Power generated from Solar PV Power Plant is transmitted to a point (sub-station) where it is distributed for consumer use.

Sub-station:The place where the generated power from solar is synchronized with utility grid and metered.

Control Room:Room housing control equipment.

Cable:A conductor with one or more strands bound together, used for transmitting electrical energy.

Junction Box:Inputs of several strings are connected to this box and taken as single output.

Current:A flow of electricity through a conductor measured in Amps.

Voltage:The rate at which energy is drawn from a source that produces a flow of electricity in a circuit; expressed in volts. It is the difference of electrical potential between two points of an electrical or electronic circuit, expressed in volts. It is the measurement of the potential for an electric field to cause an electric current in an electrical conductor.

Grid:A system of high/ low tension cables by which electrical power is distributed throughout a region.


TMB is one of the strongest scheduled commercial banks from South India.The bankhas been facing severe power outages with load shedding of more than 6 hrs per day. The Tamilnadu Government in its recent Solar Policy has introduced 6% Solar Purchase Obligation (SPO). As per this policy all HT consumers including industrial units will need to meet 6% of their total power requirements by using solar power from Jan 2014.

In order to meet this policy mandate and to overcome the power shortage and meet long term energy saving benefits, the management of the company plans to introduce solar power in TMB branches to power the lights, fans & computers, AC, pump used in the bank. For this purpose the management has invited us to prepare aDetailed Project Report (DPR) withthe financial and technical viability for setting up a solar power plant.

ThisDPR providestechnicaldetailsandoverallcosts/calculationforthefeasibilityoftheproject and lays the foundation for using solar power in TMB Banks.

The solar power plants have been designed using battery backup. The solution will use solar power as the primary source of power, with EB and Battery serving as backup.

Details / TMB
M.M. Kovilur Branch
Targeted Load / Fans, Lights & Computers, printers, Air Conditioners/pump
Required SPV capacity / 12 kW
Proposed Solar Plant / 12 kW
Capability of solar plant / 100%
Battery Capacity / 96 V 450 AH X 1 NOS
96 V 300 AH X 1 NOS
PCU / 6 KW x 2 Nos
Connected load / 6000


Powerisavitalinput foreconomicdevelopmentandsustenanceofmoderneconomy.However,providing adequateandcleanpowertofacetheever-growingenvironmentaldegradationhasbeenagreat challengeofthecurrentcentury.Renewableenergydoesnotpollutetheenvironment;thewayburningoffossilfuelsdoes.Renewableenergysourcesarelimitless and willnotbeexhaustedthoughfossilfuelwillbe gradually exhaustedin courseoftime.

ThefinancialcostofRenewable energyapplicationsis notalwayscheapbutiftheenvironmentalcostsofusingfossilareaccountedfor,renewableenergywinshands-down. Therearealsoindirectsavingson healthcosts astherearenoharmfulemissions.

Indiaisatropicalcountryandhas abundantSolarIsolationthroughoutthecountryfor mostpartoftheyear.Sincetheseasonalvariationismarginalsolarenergy canbeharnessedeconomicallythroughouttheyear.

Frequent unavailability of power from the grid is a critical problem faced by Indian industries, and with the Indian industry growing at a hectic pace, this deficit is even more harmful.

According to a recent study carried out by the Manufacturers' Association for Information Technology (MAIT) and US-based power distribution solutions provider Emerson Network Power, India Inc lost Rs 43,205 crores (about $10 billion) in 2008-09 due to power outages. The revenue loss due to power failure grew at an average of 11.9% in the past five years.

Major industries facing the problem include textiles, leather, cement, paper, sugar mills, ceramic industries etc. These industries are energy intensive in nature and thus power costs form the most critical cost component.

Many large companies have resorted to having their own captive power plants. Many industries rely to a large extent on diesel for backup power. Solar PV based power production could be an attractive option.

In Summary, the benefits of using solar PV are:

  • Powerfromthesunisclean,silent,limitlessandfree
  • PhotovoltaicprocessreleasenoCO2,SO2orNO2gaseswhicharenormally associatedwithburningfinitefossilfuelreservesanddonotcontributetoglobalwarming
  • Photovoltaic’sarenowaproventechnologywhichisinherentlysafeas opposedtootherfossilfuelbasedelectricitygeneratingtechnologies
  • Solarpowershallaugmenttheneedsofpeakpowerneeds
  • Incentives from the Government for setting up solar power plants like Subsidy, Accelerated Depreciation & Renewable Energy Certificates
  • Increasethegridreliability(i.e.voltageandfrequency)
  • Reducethetransmissionlinelosses
  • Assistsinmeetingrenewableportfoliostandards.

Demand Analysis & Justification of the Project

Solar power potential in india

India is located in a sunny belt of the earth, receiving abundant radiant energy from the sun. The daily average global radiation is around 5.0 kWh/m2 in north-eastern and hilly areas to about 7.0 kWh/m2 in western regions and hot dessert areas with the sunshine hours ranging between 2300 and 3200 per year. In most parts of India, clear sunny weather is experienced for 250 to 300 days a year. The annual global radiation varies from 1600 to 2200 kWh/m2.



Tamilnadu has high solar insolation (5.6 to 6.0 kWh/sq mt) with more than 300 clear sunny days in a year. With substantial solar insolation and declining solar power costs there is a remarkable opportunity in the solar energy domain.




Basically Solar PV Systems can be classified into two types. The first and the oldest is “Stand Alone” and the second which is rather new is “Grid Interactive”. Common examples of Stand Alone Systems are Solar lantern, Street Lighting System, Home Lighting System etc. Systems that interact with the utility power grid and have no battery backup and systems that interact and include battery backup as well are known as Grid Interactive Systems.


This type of system only operates when the grid power is available. Since grid power outages are rare, this system will normally provide the greatest amount of bill savings to the customer against investment. However, in the event of an outage, the system is designed to shut down until utility power is restored. The inverter switches to “sleep mode” and awaits restoration of grid power. Once grid power restores the inverter synchronizes itself to grid and starts feeding power into the grid.


This type of system operates in grid connected mode when the power grid is available. However, in the event of an outage, the system is designed to operate in standalone mode and starts powering dedicated loads, until utility power is restored. The inverter switches to “standalone mode” and awaits restoration of grid power. Once grid power restores the inverter synchronizes itself to grid and starts feeding power into the grid.


PV Array

A PV Array is made up of PV panel which in turn has several PV modules. These PV modules have environmentally-sealed collections of PV Cells which converts sunlight to electricity. The technical details of the solar modules proposed are attached in the form of catalogues.

Balance of System Equipment (BOS)

BOS includes module mounting structures and electrical harness systems used to integrate the solar modulesinto the structural and electrical systems. The electrical wiring systems include Junction Boxes for paralleling,fuses/switches, surge suppressors for the dc side.

The major components of the BOS are the Inverter and the Controllers. These form the brain of the systemwhich does multi operation. Some of the major operations are intelligent charging of the battery bank,managing the charge level, conversion of Direct Current to Alternating Current and Grid Synchronization.The other important BOS is the Battery Bank. For off grid usage this component provides the power storageoption. The performance of an off grid system depends on how efficiently the Battery stores power and

supports the load when called for. Different type of Secondary storage batteries are used all over the worldbut the commonly used is the Lead Acid type.

Module mounting system:

The module mounting structure is designed for holding suitable number of modules in series. The frames and legassembles of the array structures is made of Mild Steel hot dip galvanized of suitable sections of Angle, Channel, Tubesor any other sections conforming to IS:2062 for steel structure to meet the design criteria. All nuts & bolts considered forfastening modules with this structure are of very good quality of Stainless Steel. The array structure is designed in sucha way that it will occupy minimum space without sacrificing the output from SPV panels at the same time.


Dr.C.Palaniappan is the Proprietor of Sun Best, has more than 30 years of experience in solar energy both in application and promotion. He did his doctorial thesis on solar agricultural drying at Milan University under young scientist award in 1986.

The pioneering work done by Dr.C.Palaniappan is recognized by international organizations like UNDP, REEEP, UNIDO,ICTP.

The solar air heating technology has been recognized by Ministry of New Renewable Energy, Tamilnadu Energy Development Agency, National Research Development Corporation.

Dr.C.Palaniappan has continued Research & Development activities in collaboration with Technical University of Munich, Germany and International Centre for Theoretical Phyiscs, Italy to bring latest technology.

Recently completed an Indo – German project with Technical university of Munich, University of Stuttgart and Anna University.

International Energy Agency (IEA), Paris world’s authority on Renewable Energy has invited Dr.C.Palaniappan in the task force 33 as a special invitee.

Since 2007, SUN BEST has installed around 2000 m2 of solar collector for Coir mattresses sheet, Turmeric drying, Latex drying, paint shop, dryoff oven, fruits and vegetables dehydration. Sun Best is promoting the solar air heater and solar water heater to the top corporate like TTK – LIG Ltd, Orchids Pharma, Hindustan Lifecare Limited, Murugappa group, TAFE, Visteon, Caterpillar, Roca Bathroom Products Pvt Ltd, L & T etc.

The green technologies developed has served more than 100 small & medium sized companies. CO2 emission equivalent to 60,000 kW thermal has been reduced annually.

A company dedicated to producing quality work & exemplary customers’ services backed by years of real world experience and established in Theni, Tamilnadu.