In-depth Analysis of Design, Installation, Erection, Testing & Commissioning (EPC) for Small Power Generation Plants (SPGP)

This analysis dives deep into the various stages involved in the EPC process for SPGPs, encompassing a complete solar power system with battery storage and export capabilities.

The detailed analysis of the design, installation, erection, testing, and commissioning (EPC) of the complete Small Power Generation Plant (SPGP) system encompasses several critical components and processes.

Let's break down each aspect as Work Breakdown System (WBS):

Phase 1 - Supply and Installation Small Power Generation Plants (SPGP) and BESS Items

• Price of Schedule No 1A : Solar PV Modules.
• Price of Schedule No 1B :? PV? Inverters
• Price of Schedule No 1C :?Module Mounting Structure (MMS)?fixed-tilt racking structure(s)
• Price of Schedule No 2A : Battery Energy Storage System? (if applicable)
• Price of Schedule No 2B : Battery? Inverters /Chargers (if applicable)
• Price of Schedule No 2C : Solar Export Energy Meter? (if applicable)
• Price of Schedule No 2C : Service Cables, Meters, Accessories and other items
• Price of Schedule No 3A : Survey & Design Services?Solar Photovoltaic (SPV) Systems
• Price of Schedule No 3B :? Survey & Design Services? Battery Energy Storage System
• Price of Schedule No 3B :? Survey & Design, Drawings for Electrical & Civil works (Drawing Section)
• Price of Schedule No 3C :? Survey, Permitting & Approvals, and Statutory Clearance? Services?Price of Schedule No 4A : Installation, Commissioning, and Other Services
• Price of Schedule No 4B :? Performance Guarantee of SPGP
• Price of Schedule No 5 : Environmental, Social, Health and Safety (ESHS) Services? (if applicable)

Phase 2 - Facility Operations and Maintenance

• Price of Schedule No 6: Operations and Maintenance of the Stand Alone Solar Photovoltaic Generation Plant

Pre-Construction Phase:

• Survey and Customer Engagement:A thorough premises survey assesses the suitability of the site for solar power generation. Factors like roof size, orientation, shading, and structural integrity are evaluated.
• Customer sensitization involves educating the customer about the benefits and functionalities of the SPGP system. This fosters clear communication and expectations including Insurance covering all risk (Fire & allied perils, earthquake, terrorist acts,floods, storms and burglary.?
• Customer data collection gathers information on the facility's energy consumption patterns. This data helps determine the optimal system size and battery storage capacity.

Detailed Design and Documentation:

Detailed design involves creating a comprehensive plan for the SPGP system. This includes:

• System layout and component selection (SPV modules, inverters, batteries, etc.)
• Structural design for module mounting systems (fixed-tilt racking)
• Electrical design, specifying wiring diagrams, cable sizing, and protection equipment
• Once the design is finalized, detailed drawings and technical specifications are prepared for all components: SPV modules, Module mounting structure, Inverters, Battery inverter/charger, Charge controllers, BESS Metering system, Cables and other Balance of System (BOS) components
• Design proposals are presented to the customer for review and approval.
• Customer Facility Database (FDB) updates: The final design details are documented and stored in the customer's FDB for future reference.
• Drawing and specification preparation: Technical drawings and specifications for all system components are prepared. These documents ensure proper installation and compliance with regulations.
• Permitting & Approvals (if applicable): The EPC company might assist with obtaining necessary permits and approvals from local authorities.

Construction and Installation Phase:

• Site Preparation and Construction Activities: Site preparation involves clearing, digging, trenching, grading, and constructing access roads to facilitate installation activities.
• Proper coordination and management of construction activities are essential to ensure timely completion and adherence to safety standards.Deployment of technical, supporting? and? security personnel as necessary and regulation of their?Duties
• Material Procurement: All necessary components for the SPGP system are procured, ensuring they meet project specifications and quality standards.
• Material Delivery:?All necessary components – modules, inverters, batteries, cables, etc. – are delivered to the site. Labor and equipment are required for delivering, unloading, and installing various components of the SPGP system.
• Module Mounting System Installation: The fixed-tilt racking structures are securely mounted on the roof or designated ground area.
• SPV Module Installation: Solar panels are carefully installed on the racking system, ensuring proper alignment and electrical connections.
• Inverter Installation: Solar inverters, battery inverters/chargers, and charge controllers are installed at designated locations based on the design plans.
• Battery Energy Storage System (BESS) Installation: The battery bank is installed in a suitable location, considering ventilation and safety requirements.
• Metering System Installation: A main meter for exporting excess energy is installed with its dedicated meter box and mounting structure. Necessary accessories like cables, terminations, and earthing are included. In some cases, the service cable (PVC insulated single/three-phase) may also be installed during this stage, connecting the SPGP to the grid.
• All cabling (AC & DC) is installed according to the design, using appropriate conduits, cable trays, and support structures. Breakers, fuses, and other protection devices are installed as per the design specifications.

Internal Wiring and Electrical Components:

• Internal wiring within the main building is completed, including a fuse cutout, distribution board, lighting points, sockets, and proper earthing. This ensures efficient utilization of the generated solar power.
• Balance of System (BOS) Installation: This encompasses all additional components needed for system interconnection and operation, such as: AC & DC wiring Breakers, fuses Meter boxes, cutouts, combiner boxes Panelboards, conduits, cable trays Relays, trenches, support structures Cabinets, sensors

Testing and Commissioning:

• Once installed, the SPGP system undergoes rigorous testing to verify its performance, functionality, and safety.
• Commissioning involves the initial operation of the system and fine-tuning to optimize its performance.
• Comprehensive testing protocols should be followed to identify and rectify any issues before handing over the system to the customer.
• System Testing:? Rigorous testing is performed on all installed components to ensure proper functionality and safety.This includes testing individual modules, string testing, inverter testing, battery system testing, and overall system performance verification.? Rigorous testing is performed on all system components, including: Electrical performance testing Safety checks and grounding verification Battery system testing Metering accuracy verification Metering accuracy and grid interconnection are also validated.

Commissioning: The entire SPGP system is brought online and undergoes final adjustments to ensure optimal performance and smooth integration with the grid (if applicable).The complete system is officially commissioned, and its operation is demonstrated to the client.

Training might be provided on system operation and basic maintenance procedures.

Post-Commissioning:

• Initial Operation: The EPC company might provide initial support during the system's initial operation to ensure smooth performance. This may involve monitoring system performance and addressing any minor issues that may arise.
• Warranty & Maintenance: The EPC company typically provides a warranty on the installed system and its components. Maintenance plans might be offered to ensure the system's long-term performance and reliability. Conducting periodical checking, testing, overhauling and preventive action. Attending breakdowns on the customer connections. Cleaning of modules.
• Regular periodic checks of the modules, inverters, BESS, Customer Connection etc., shall?be carried out as a part of routine preventive maintenance.
• Preventive maintenance shall include checking of all electrical connections, cables etc.?wherever required or any other activity that may be required for proper functioning of the?installation and Consumer Connections.
• In order to meet the maintenance requirements, stock of consumables are to be maintained?as well as various recommended spares by the manufacturer.
• Particular care shall be taken for outdoor equipment to prevent corrosion. Cleaning of the junction boxes, cable joints, insulators etc. shall also be carried out frequently.
• Resistance of the earthing system as well as individual earthing is to be measured and?recorded frequently. If the earth resistance is more than 1-ohm, suitable action is to be taken to?bring down the same.
• According to the recommendations, stock of special tools and tackles shall be maintained?for Modules, inverters and other major electrical equipment.
• Maintain accurate and up-to-date operating logs, by? logging of voltage, current, power factor, power and energy output of?the SPGP,? records and reports regarding the?operation and maintenance of the Plant which shall include details of power output, other?operating data, repairs performed, status of equipment and all other such records to be?maintained for the complete O&M period.

ENVIRONMENTAL, SOCIAL, HEALTH AND SAFETY (ESHS) SERVICES?(if applicable)

• Sprinkling water on excavated soil when necessary and where water is available to reduce?dust
• Worksite Safety, at height, accidents and Health Hazards to employees Provision of all appropriate PPEs to the contractor’s employees Necessary and appropriate warning signs in various points that are risky Provision of the first aid kits on site with trained first aiders.
• Fire hazards and outbreaks Labelling / signage of all equipment and compartments?Adequate fire fighting appliances at all sites to meet any emergency resulting from ignition?of the SPGP system of a fire.

4. Additional Considerations:

• Safety: Safety protocols are paramount throughout the EPC process, with adherence to electrical safety regulations and proper use of personal protective equipment (PPE).
• Labor: The EPC service provider covers the labor costs for all activities, from delivery and unloading of equipment to installation, commissioning, and initial system operation.
• Training: Depending on the agreement, the EPC provider may offer basic training to the customer on system operation and maintenance procedures.
• Warranties: The EPC service provider typically provides warranties on the installed equipment and workmanship for a specified period.

In summary, the design, installation, erection, testing, and commissioning of a complete SPGP system involve a multi-faceted approach encompassing site assessment, customer engagement, technical design, procurement, construction, and testing. Attention to detail, compliance with regulations, and effective project management are essential for the successful implementation of such a project.

By understanding these intricate details involved in the EPC process, project owners and stakeholders can gain a comprehensive understanding of the scope of work and the expertise required for a successful SPGP installation.