912 kWp Solar Rooftop for Industries for a Leading Forging Plant in Pune
Sep 16
912 kWp Solar Rooftop for Industries for a Leading Forging Plant in Pune
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912 kWp Solar Rooftop for Industries for a Leading Forging Plant in Pune
From heavy presses to heat-intensive furnaces, forging plants run on serious power. This case study follows how a leading Pune manufacturer used a 912 kWp industrial rooftop solar system to turn idle roof space into reliable energy, without upfront investment. In simple terms: zero capex, lower daytime electricity bills, and measurable CO₂ reduction. We’ll walk through the project setup, on-site challenges, engineering choices, and the numbers that matter, so you can see what a similar rooftop solar PV project could do for your facility.
Project Overview: 912 kWp Industrial Solar Rooftop Installation
A precision-forging major in Pune partnered with GSE Renewables for the installation of an industrial solar rooftop project that adds 912 kWp of clean capacity to its plant. The system is now live and exporting green power to the factory’s internal grid.
Quick stats
- Plant capacity: 912 kWp large solar rooftop system
- Location: Pune, Maharashtra
- Industry: Precision forging and machining for automotive and engineering OEMs
- Commissioning: 2025
- Business model: Zero investment OPEX/PPA model
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According to MNRE, India has ~19.9 GW of grid-connected rooftop solar already installed, with Maharashtra contributing ~3.75 GW, underscoring why Pune’s industrial belt is primed for large rooftop PV projects. Sources: MNRE Rooftop/RE progress dashboard |
Why such a sizeable rooftop solar PV project for an industrial facility? Forging operations depend on heavy electrical loads for presses, furnaces and utilities. Daytime consumption is high and predictable, which makes rooftop solar systems on industrial buildings ideal to shave energy costs, offset grid consumption and cut Scope-2 emissions. This installation of a large industrial solar rooftop project turns unused roof space into a performing energy asset that contributes power every sunny hour.
Why This Project Matters
Across India, manufacturers are turning to solar panels for manufacturing units to create long-term cost visibility and sustainability gains. This case study is a strong regional example of a strategic industrial rooftop deployment. It lowers the client’s tariff exposure, strengthens energy independence during working hours and supports corporate net-zero pathways with a proven industrial solar solution.
For this business, the 912 kWp solar power plant for business replaces a significant share of day-time grid draw with green electricity. Because the plant invests in a solar rooftop asset through a zero-capex PPA structure, savings start from day one while preserving capital for core production upgrades. The system’s output flows directly into the plant’s distribution board, a textbook application of rooftop solar photovoltaic (PV) systems for industry.
Why industry first: Industrial consumers account for roughly 41% of India’s electricity use (≈594 BU of 1,440 BU in 2022–23), so shifting day-time demand to on-site solar has an outsized impact on both cost and emissions. Source: CERC Report on Short-Term Power Market in India 2023-24 |
Location & Infrastructure Challenges
The site consists of multiple production bays covered with high-strength metal sheds and select RCC office blocks. A typical industrial solar roof installation must respect process safety, crane movement, and equipment clearances, and this facility was no different. Key considerations included:
- Roof condition and load-bearing: Structural checks verified purlin spacing, sheet gauge and truss integrity to safely host the planned rooftop solar capacity.
- Thermal and vibration zones: Forging lines generate heat and intermittent vibrations. Array layouts were planned to maintain safe distances from stacks, furnaces, make-up air units and overhead material handling.
- Weather exposure: Pune’s monsoon demands robust drainage and wind-resistant design. Walkways and maintenance aisles were aligned with roof slopes so water pathways remained unobstructed.
- Operational continuity: All works were scheduled to avoid production downtime and to keep egress routes open.
The result is a resilient solar rooftop for industries solution built for year-round performance in a demanding shop-floor environment.
Key Highlights or Solutions for the 912 kWp Rooftop Solar Plant
GSE’s engineering team delivered a tightly optimized, on-grid industrial rooftop solar system designed for high generation per square foot.
- PV modules: High-efficiency mono-PERC modules were selected to maximize kWh from available roof area. Where shadows were minimal and reflectance was favorable, bifacial strings were introduced to lift yield without structural additions.
- Inverters and layout: Distributed string inverters increase uptime and simplify O&M. Independent MPPT trackers limit mismatch losses across differently oriented sheds in the rooftop solar array.
- Mounting solution: Aluminum rail structures with SS fasteners were anchored using non-penetrating clamps on metal roofs and chemical anchors on RCC parapets. All design followed wind tunnel data and IS standards for mechanical stability.
- Cable and protection: UV-resistant DC cabling, DC combiner boxes with surge protection devices, and AC protection at LT panels maintain safety throughout the grid connected rooftop solar PV system.
- Monitoring and SCADA: A utility-grade energy meter at the point of interconnection feeds live data to a cloud dashboard for performance tracking, alarms and monthly PR analysis.
- Safety protocols: Work-at-height kits, lifelines, hot-work permits, and lockout-tagout procedures were deployed across the site. Fire safety clearances and lightning protection were part of the base design.
Compliance: Net-metering and CEIG approvals were processed in sequence to make the On grid solar rooftop fully compliant with local policies.
Energy Output & Financial Benefits
Industrial clients measure success through data. This plant’s metered performance and design assumptions translate into clear KPIs and a solid business case for solar energy for power generation.
1) Performance metrics (Year-1 model):
- Installed DC capacity: 912 kWp
- Estimated annual solar energy generation: 13,13,280 kWh (1.313 GWh)
- Specific yield: ~1,440 kWh/kWp-year (well-optimized for Pune)
- Capacity Utilization Factor (CUF): ~16.4%
- Target Performance Ratio (PR): ~79–82% (module quality, low losses, good O&M)
- Mid-day demand shave: up to 650–700 kW during clear-sky hours, reducing draw from the grid when production is highest.
2) Financial outcomes:
- Estimated annual energy-cost savings: ₹72,23,040 (based on the client’s tariff vs. PPA; ≈ ₹5.5 saved per kWh generated).
- Model: Zero-capex OPEX/PPA, so savings are visible from the first month; O&M and insurance are included in the tariff.
- TOD advantage: Pune’s working hours align with high irradiance; shifting day-time consumption to PV reduces exposure to higher day-slot tariffs and fuel-surcharge volatility.
- 10-year savings lens: Assuming a modest 3% annual increase in the grid–PPA spread and 0.6%/yr PV degradation, cumulative avoided cost is ≈₹8.3 crore over 10 years (illustrative, site-specific bills will refine this).
- Carbon accounting: Client baseline shows ~745 tCO₂/year avoided. Using CEA FY 2023–24 grid factors (Average 0.727; Build Margin 0.552; Combined Margin 0.757 tCO₂/MWh), avoided emissions range ~725–995 tCO₂/year depending on your ESG methodology. This dual disclosure keeps sustainability reports audit-ready.
Lifetime generation: With 0.6%/yr degradation, 25-year output totals ~30 GWh, meaning tens of gigawatt-hours of solar energy generation displacing grid electricity over the asset life.
What it means for operations:
The solar power displaces day-time grid consumption, shaving energy charges and contributing to demand management. For a forging plant with steady day loads, that translates to predictable per-unit cost relief, improved ESG scores, and better resilience against tariff escalations.
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GSE Renewables as EPC Partner
Choosing the right partner is as important as choosing the right technology. As a Solar EPC Company, GSE Renewables delivered end-to-end scope with production-first planning, what you’d expect from experienced Solar EPC Contractors serving heavy industry.
1) Engineering & Design
- Feasibility & simulations: Roof-wise surveys, shade studies, and PVsyst simulations to lock string sizing, tilt/orientation, and expected PR/CUF.
- Structural due diligence: Truss and purlin checks for metal sheds; RCC audits where applicable. Designs reference IS 875 (Wind Loads), IS 800 (Steel Design) and OEM fastener pull-out data.
- Electrical design: Single-Line Diagrams, protection coordination, earthing & lightning layouts as per CEA Safety Regulations; SPD selection per IEC/IS; cable routing to keep voltage drop and thermal rise within limits.
- Compliance envelope: Modules to IEC 61215/61730, inverters to IEC 62109; anti-islanding compliance (IEC 62116 / IEEE 1547 practices) and utility interconnection norms.
2) Procurement (Bankable Hardware)
- Modules: High-efficiency mono-PERC (bifacial used on select bays for albedo gains), with PID-resistant BOM and 25-year performance warranty.
- Inverters: Distributed string architecture with multiple MPPTs to minimize mismatch across differently oriented sheds; integrated AFCI and Type-II SPD.
- BOS: UV-stabilized DC/AC cabling, aluminum/SS mounting with corrosion protection, type-tested switchgear, certified fall-arrest systems.
- Quality gates: Factory Acceptance Tests (as applicable), inbound QA, and batch-wise traceability for critical components.
3) Construction & Commissioning
- Method statements: Work-at-height plans, hot-work permits, LOTO, and crane/aisle coordination to avoid production disruption.
- Mechanical & electrical works: Torque-controlled assembly, string continuity & insulation testing, IV-curve tracing, polarity checks, and inverter-level commissioning.
- Grid integration: Protection relay checks, anti-islanding tests, and synchronization at the LT panel/point of common coupling; documented SATs and Energisation Reports.
- Safety record: Zero lost-time incidents (LTIs) during execution; daily toolbox talks and supervisor sign-offs.
4) Approvals & Net-Metering
- Utility interface: Application filing, drawings, inspections and CEIG approvals sequenced to keep the energisation timeline predictable.
- Documentation: As-built drawings, test certificates, warranties, and O&M manuals handed over in a single close-out pack.
5) Monitoring, O&M & SLAs
- 24×7 monitoring: Utility-grade meter at PCC, plant SCADA with web dashboard, alarms, and KPI tracking (PR, CUF, inverter uptime, specific yield).
- Preventive O&M: Cleaning schedules tuned to season and soiling index; thermography, torque audits, earthing & SPD checks; firmware updates.
- Response commitments: Typical <4-hour remote response and <24–48-hour on-site restoration for critical events; spare-kit maintained locally for fast turnarounds.
- Reporting: Monthly PR/CUF reports with variance analysis vs. model; quarter-yearly performance reviews and energy-saving validation aligned to your ESG reporting cycles.
Thinking about an industrial solar rooftop for your factory, warehouse or processing unit in India? Talk to GSE Renewables for a site-specific design, bankable financial model and a delivery plan that respects your safety and production schedules.
Use our quick solar calculator to estimate energy output and cost reduction for your facility. We will benchmark your roof, simulate yield, and propose solar solutions for industrial requirements that fit CAPEX or OPEX models.
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Frequently Asked Questions
What is the ROI and payback period of industrial rooftop solar?
Under a CAPEX model in Maharashtra, typical simple payback ranges from 3 to 4.5 years depending on tariff, module efficiency and policy benefits. Under an OPEX/PPA model, there is no upfront capex and you start seeing positive cash flow from the first month.
What are the maintenance requirements for a rooftop solar system in industries?
Planned O&M includes periodic module cleaning, string-level health checks, thermography, earthing and SPD inspections, and firmware updates. With remote monitoring and a preventive schedule, annual availability above 99 percent is realistic.
Are there government subsidies or tax benefits for industrial solar projects?
Subsidies are generally targeted to residential and MSME schemes and vary by state. For businesses, savings mainly come from net-metering or net-billing, accelerated depreciation where applicable, and concessional policies on open-access or group-captive where relevant.
How much energy can a 912 kWp rooftop solar system generate annually?
At Pune’s solar resource, a well-engineered plant typically generates around 1.2 to 1.4 GWh per year. This project is modeled at 13,13,280 kWh annually, with actuals tracked on a monthly PR dashboard.
What industries benefit the most from rooftop solar installations?
Energy-intensive sectors with stable day loads benefit greatly, including forging, foundry, automotive components, food processing, textiles, pharma and logistics warehousing. Rooftop solar reduces the levelized cost of electricity while improving ESG scores.
Is rooftop solar feasible for old factory buildings?
Yes, subject to a structural audit. We verify truss integrity, purlin spacing and sheet condition, and then choose mounting solutions that keep loads within allowable limits. Where required, we reinforce selective bays or switch to RCC sections.
How much roof space is required for a 912 kWp industrial solar plant?
Space depends on module wattage and walkway design. With high-efficiency mono-PERC, plan for roughly 6,000 to 7,500 square meters including maintenance aisles and setbacks. A detailed layout is part of our site survey.
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