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Tata Motors – India.

Reduction in the effects caused by climate change through green energy initiatives.

Need

Tata Motors Ltd., an Indian multinational automotive manufacturing company offers a wide range of commercial and passenger vehicles to the Indian customer base. The company is committed to reducing the effects of climate change by adopting green initiatives in their operations. The organization aimed to generate about 20% of its annual on-premise power requirements through rooftop solar power plants that offer affordable clean power and reduce the overall carbon footprint of the company.

Challenges

  • To install the rooftop solar power plant on multi-orientation metal and RCC roofs of extremely large manufacturing facilities of commercial vehicles.
  • To optimize the power injection points of all the solar power rooftops within the premises to reduce power loss and gain maximum power generation.
  • To manage safe access for a large workforce along with the movement of power plant material on the roof without hindering manufacturing operations.
  • It was mandatory to store materials at the designated spots within the campus and conduct material movement only on weekends and holidays as per the material movement policies of Tata Motors.
  • To secure permissions from various departments of Tata Motors for constructing solar plants on their building roofs.
  • To achieve maximum savings on grid power expenses by operationalizing the power plant in phases while adhering to stringent material, workforce, installation, and EHS guidelines provided by Tata Motors.

Solution

  • BECIS considered various viable metal and RCC rooftops of the factories for the power plant installation. Thereafter curated a rooftop solar power plant which consists of 325 Wp and 330 Wp high capacity polycrystalline solar modules, which have relatively lower temperature coefficients connected to the 60 KW and 40 KW multi MPPT inverters that operate on a low input voltage.
  • As per the safety guidelines of Tata Motors for metal roofs, a robust Module Mounting Structure with HDG coating was used instead of a regular aluminium long rail.
  • For double resistance against wind uplift and other encountering forces, the base clamp anchored at two crests with the SDF. (self-drilling fastener)
  • The power is evacuated at various substations directly at the busbar level through dedicated metering CTs (Current Transformers) and meters.
  • Each solar power plant has been connected to field ICB (Intelligent Circuit Breaker) & an evacuation MCB (Miniature Circuit Breaker) at various control rooms as per the guidelines issued by Tata Motors Ltd.
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