OFF GRID SOLAR POWER SOLUTION FOR TTK

PRESTIGE DETAILED PROJECT REPORT

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TABLE OF CONTENTS

GLOSSARY OF TERMS .................................................................................................................................... 3

EXECUTIVE SUMMARY .................................................................................................................................. 5

INTRODUCTION ............................................................................................................................................. 7

MANAGEMENT OBJECTIVES FOR INSTALLING SOLAR POWER ................................................................... 10

DEMAND ANALYSIS & JUSTIFICATION OF THE PROJECT ............................................................................. 12

SYNOPSIS OF THE PROJECT ......................................................................................................................... 15

OPERATION METHODOLOGY ..................................................................................................................... 19

IMPLEMENTATION METHODOLOGY .......................................................................................................... 23

ABOUT SUN BEST ........................................................................................................................................ 34

CONCLUSION ............................................................................................................................................... 38

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GLOSSARY OF TERMS

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/ (m² day)) (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.

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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.

Lightning Arrestor: Device used to protect all the components from

lightning strikes.

Transformer: An electrical device by which alternating current of one

voltage is changed to another voltage.

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

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EXECUTIVE SUMMARY

TTK Prestige has a manufacturing unit in Myleripalayam near Coimbatore.

The factory has a limited sanctioned load of 490KVA from TNEB while the peak

connected load is 810KVA. The additional power is currently being met by a set

of 2 x 320KVA & 1 x 1010KVA Diesel Generators. With the cost of diesel rising

rapidly, the company is planning to install a solar power plant that will power

100 KW load during sunny period with battery back up so as to minimize the

use of at least one 320KVA DG and get considerable savings on diesel costs.

This DPR provides technical details and overall costs/calculation for the

feasibility of the project. The proposed solution will provide solar power as a

standalone off-grid solution to power 100 KW load of the factory during sunny

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period with battery backup. The system will able to provide 75 -80% of load.

With this the objective to avoid running the 320KVA DG will be met for at least

290 days per year.

The layout of the proposed solar power plant is given in the figure below:

100

100 KVA

Solar output 100 KW

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The following table gives the summary of the proposed project:

Targeted Load Factory Loads

Connected Load 810KVA (648 KW)

Proposed Solar Plant 100 KW

Area Required 10,000 Sq Ft of Un-shaded Space

(space available above Factory Polish area & Canteen roof)

Annual Solar Energy Generation 1.66 Lakh Units Per Year

Solar Project Cost*** Rs.165.1 Lakhs*

Government subsidy** Rs. 49.53 Lakhs

Tax benefit Rs. 47.94 Lakhs

Net investment Rs. 68.04 Lakhs

ROI without subsidy for diesel replacement

3.95 Years

ROI with subsidy for diesel replacement

2.26 Years

.

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INTRODUCTION

Power is a vital input for economic development and sustenance of modern

economy. However, providing adequate and clean power to face the ever-

growing environmental degradation has been a great challenge of the current

century. Renewable energy does not pollute the environment; the way burning

of fossil fuels does. Renewable energy sources are limitless and will not be

exhausted though fossil fuel will be gradually exhausted in course of time.

The financial cost of Renewable energy applications is not always cheap but if

the environmental costs of using fossil are accounted for, renewable energy

wins hands-down. There are also indirect savings on health costs as there

are no harmful emissions.

India is a tropical country and has abundant Solar Isolation throughout the

country for most part of the year. Since the seasonal variation is marginal

solar energy can be harnessed economically throughout the year.

Shortage of power is a critical problem faced by Indian industries, and with the

Indian industry growing at a hectic pace, this deficit is even more harmful.

Major 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 additional power. With the

cost of diesel increasing rapidly, it is becoming economically unviable to

continue to run on diesel generators. With the prices of Solar PV becoming

attractive, several industries are considering solar energy to replace their diesel

generators.

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In Summary, the benefits of using solar PV are:

Solar power will reduce the cost of production as it is cheaper than

diesel with a payback of around 2.26 years.

Solar power will augment the needs of peak power needs of the factory

Incentives are available from the Government for setting up solar power

plants like Subsidy, Accelerated Depreciation & Renewable Energy

Certificates

Solar power will help in meeting the Solar Purchas Obligation of the

TN state government.

Power from the sun is clean, silent, limitless and free

Photovoltaic process release no CO2, SO2 or NO2 gases which are

normally associated with burning finite fossil fuel reserves and do not

contribute to global warming

Photovoltaic’s are now a proven technology which is inherently

safe as opposed to other fossil fuel based electricity generating

technologies

Increase the grid reliability (i.e. voltage and frequency)

Reduce the transmission line losses

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MANAGEMENT OBJECTIVES FOR INSTALLING SOLAR POWER

HIGH COST OF RUNNING DIESEL GENERATORS IMPACTING

BOTTOM LINE

TTK Prestige has a sanctioned load of 490 KVA while the connected load is as

high as 810KVA. In order to overcome the demand the factory is using a set of

2 x 320KVA & 1 x 1010KVA Diesel Generators. Over the last 10 years diesel

prices have increased by 158% at a compound rate of approximately 16% per

annum. With diesel prices becoming deregulated, the cost of using diesel is

expected to go up rapidly. At current bulk purchase prices, the cost of using

diesel is around Rs. 20 per unit. At this cost the payback by using solar to

replace DG is very attractive at around 2.26 years.

The chart below depicts the increase in retail price of diesel over the last

decade. Ref: www.mypetrolprice.com

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SOLAR PURCHASE OBLIGATION

In its recent Policy statement TN Government has introduced a Solar Purchase

Obligation of 6% for all HT consumers with effect from Jan 2014. The

obligated consumers may fulfill the SPO by:

Generating captive solar power in TN equivalent or more than their SPO

Buying equivalent to or more than their SPO from other third party

developers in TN

Buying RECs generated by solar projects in TN

Purchasing power from TANGEDCO at Solar Tariff

ENVIRONMENTAL CONCERNS

The company policy is to ensure healthy, safe and secure environment for its

employees. The Green Energy produced by solar power will not only help the

company in meeting its energy demands but would also help in meeting

international standards.

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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.

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PROJECT LOCATION IN TAMILNADU

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.

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SYNOPSIS OF THE PROJECT

AVAILABLE DATA

Location of the Plant Mayileripalayam, Coimbatore

Site Coordinates Lat: 10.87

Long: 77.00

Sanctioned Load 490KVA

Connected Load 810KVA

Power Cut 5 Hrs

Avg TNEB Bill over last 7 months Rs. 4.5 Lakhs per month

Avg. Cost of Grid Per Unit Rs. 7.5 Per Unit

Avg. Cost of Diesel Per Unit *Rs. 18 Per Unit

Roof Area Available Factory Policsh Area: 1860 Sq Mt

(20,020 Sq Ft)

Canteen Area: 1050Sq MT (11302

Sq Ft)

Total Area: 31,322 Sq Ft

* The bulk price of diesel is currently at Rs.60/liter. The 320KVA generator

consumes around 40 liters per hour which is equivalent to Rs. 83.5 Lakhs per

year. As this solution is designed to replace the 320DG for most of the year, we

have taken this annual cost of diesel for 320KVA DG for calculating the

payback.

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ESTIMATED SOLAR POWER GENERATION FROM THE PROPOSED

PLANTS

As per the historical data available with Central Energy Regulatory

Commission (CERC) of India solar power plants based in India have

demonstrated a PLF of 19%. At 19% PLF the annual solar power generation for

100KW solar plant is 166 MWh.

PAYBACK ANALYSIS

ASSUMPTIONS

As the solution is primarily designed to avoid running the 320KVA DG,

the payback of the solution is based on comparing the solar costs with

the diesel cost

Base Price of diesel is taken at Rs. 60/liter which is the current market

price for bulk consumers

Diesel cost is increased by 10% every year as per historical data given

above.

Maintenance of Diesel Generator (as given by the company managers)

has been taken at Rs. 0.50/kWH.

Based on the bills of the last 6 months, the average cost of electricity

from TNEB is Rs. 7.5/unit

Last year the electricity prices were increases by average 37%. TN

government is likely to increase the price of electricity on an annual basis

to tide over the financial crisis of TNEB. On a conservative basis, it is

assumed that electricity price will increase by 8% to 10% per year over

the coming few years.

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AMC cost for solar plant is 1% of the Capital Cost. AMC is increase by

5% every year.

80% Accelerated Depreciation for the 1st year has been taken into

account for solar projects.

PAYBACK CHART FOR 100 KW SOLAR PLANT – SOLAR VS DIESEL

Annual Solar Energy Generation 1.66Lakh Units Per Year

Solar savings (1.66 Lakh Units Per Year x Rs. 18/Unit)

Rs.29.88 Lakhs

Solar Project Cost*** Rs.165.1 Lakhs*

Government subsidy** Rs. 49.53 Lakhs

Tax benefit Rs. 47.94 Lakhs

Net investment Rs. 68.04 Lakhs

ROI without subsidy for diesel

replacement

3.95 Years

ROI with subsidy for diesel replacement

2.26 Years

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SOLUTION DESIGN FOR 100KW OFF GRID SOLAR SYSTEM

Solar Photovoltaic power generator consists of solar modules in series and

parallel connections; these convert solar radiations into DC electrical power at

the predetermined range of Voltages whenever sufficient solar radiation is

available. The individual crystalline solar cells are connected together in

module (in series connection), which are hermetically sealed to survive in

rugged weather conditions and ensures optimum performance during its long

life. In order to achieve a higher system voltage, modules are installed in a row

arrangement, called a string. A higher system voltage has the advantage of

lesser installation work, higher efficiency of the entire plant and usage of

smaller cross section cables. Calculated no. of strings is connected in parallel

by cables in Junction Boxes. These junction boxes not only act as a

junction point but also monitor each string output which will be fed to the

central monitoring and analysis system. Outputs from many such junction

boxes are connected in parallel in the Main Combiner Box (MCB). This Main

Combiner Box output is fed to the Off Grid Inverter to invert solar

generated DC power in to conventional 3 phase AC power. O f f Grid

Inverter operate on MPPT (Maximum power point tracking) mode to ensure

maximum output from the solar generators at di f f erent ambien t

conditions. These inverters use higher system voltages to reach very high

efficiency of 98%. Furthermore, installations can be expanded with additions

of more modules without problems.

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OPERATION METHODOLOGY

The proposed solution is designed with 100KW Solar Panels, 100 KW Off

Grid Power Conditioning Unit (PCU) & 1700Ah /240V Battery bank. The

load connected will be 100KW. During the day, solar power will be

supplied directly to the 100KW load and in parallel, the battery bank will

also get charged. When the solar power is low, the power to the loads will

be supplemented with battery power.

The system will be provided with communication ports which will enable

local and remote monitoring and control.

POWER PLANT CONFIGURATION

S.NO ITEM Qty

1 Solar Poly PV Modules (in 200W-250W range)* 100KW

2 Module Mounting Structure As per site

area

3 100KVA Off Grid PCU 3 Phase with MPPT Controller 1 No

4 1700Ah/240V VRLA Battery Bank 1 No

5 Array Junction Boxes, Main Junction Boxes, DC

Distribution Board

Suitable

Number

6 String Monitoring & SCADA Suitable

Number

7 AC Distribution Board 1 No

8 1C x 4 Sq mm PVC Cu. Cable (Array to AJB), 1C x 25

Sq mm PVC Cu. Cable (AJB to MJB, 31/2C 16 Sq mm

PVC Cu Cable (Inverter Output to Load)

Suitable qty

9 UG Cable from Main Junction Box to Bus Bar* 100 mts

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10 Earthing Kits Suitable

Numbers

11 Lighting Arrestors Suitable

Numbers

The products will meet all international and domestic certification and quality

standards approved by MNRE like TUV, IEC, MNRE, BIS, UL & MCS.

*As per the government of India regulation, the SPV panels supplied are to be

Indian origin having standards IEC 61215 / IS14286.

OFF GRID POWER CONDITIONING UNIT (PCU)

The Off Grid PCU is designed to integrate renewable sources like solar with

batteries to provide a completely standalone power plant. The PCU output

is designed to operate independently without any other power source and

replace the existing DG. The units are fitted with data logger, web server, a

graphical display for showing operating data and a USB port for installing

firmware updates. These inverters are sophisticated bi-directional power

conditioners featuring advanced fast control algorithms which

accommodate a range of power sources and storage technologies. This

ensures high quality power output under varied or cloudy conditions and

supports high levels of solar penetration, including zero diesel fuel

consumption power systems. If and when required it can also be integrated

with the DG

EARTHING & LIGHITNG PROTECTION

The Earthing of all outdoor equipment and provision of associated earthing

systems, electrodes and connections shall be in accordance with the

recommendations in the latest IEEE 80/IS 3043.

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GROUNDING SYSTEM

The grounding design calculation shall conform to ANSI / IEEE Standard

80-2000. Earth electrodes shall be provided throughout the plant areas along

with the main earth grid. The number of earth electrodes shall be according to

achieve the total earth grid resistance less than one (1) ohm. Earth electrodes

shall be provided in earth pits. The earth pits shall be of two types namely

treated with test links and untreated. Earth electrodes shall be of heavy duty

GI pipes, 40mm dia and 3 meter long. The main buried grid conductors shall

be connected to all the earth electrodes to form a total earth grid.

GROUNDING MATERIAL

Galvanized steel flats of required size shall be used as per approved design.

Treated earth pits shall conform to relevant INDIAN Standards. The earth

grid shall be installed specified / approved depth of minimum 600mm.

EQUIPMENT EARTHING

The frames of all electrical equipment and structural steel work shall

be earthed by connection to earth grid by branches of same cross sectional

area of the earth grid.

LIGHTINING PROTECTION SYSTEM

Power plant needs protection against Lighting. The system will be designed

as per IS: 2309 and Indian Electricity Rules.

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Vertical air termination of 40mm diameter, 3 M long shall be provided

above highest point of array to provide radius of protection full array.

STRUCTURAL MOUNTING EQUIPMENT*

SR.NO. ITEM

1.0 Type Ground / Roof Mounting

2.0 Material MS Galvanized

3.0 Overall dimension As per design

4.0 Coating Hot dip (Galvanized) Minimum of 130 Micron size

5.0 Wind rating 150 km / hr

6.0 Tilt angle 15°

7.0 Fixing type SS 304 Fasteners

*Mounting for panels only included. The support frame for solar SPV panels

which is made of Zinc coated hot dipped galvanized iron frames of height ½ m

and 1 m on the other side – any higher support or basic frames + civil works

have to be done by the use under our directions.

The panel mounting structure including the solar panels will weigh 20 Kgs per

sq mt. In some locations, the roofs may require reinforcement to increase the

load bearing weight to support the mounting structures. Structural and civil

costs to increase the load bearing weight of the roofs to support the solar panel

structure is not included in the scope of work. For ground mounted systems

the cost of clearing the land has not been included in the scope of work.

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IMPLEMENTATION METHODOLOGY

The most essential aspect regarding the implementation of this project is to

ensure that the project is successfully completed within the schedule. A

good planning, scheduling, and monitoring program is imperat ive to

complete the project on time and without cost overruns.

The project zero date start once the kick- off meeting has taken place and

contract has been signed.

PROJECT IMPLEMETATION STRATEGY

It is envisaged that the project will have the below mentioned phase

of activities. These phases are not mutually exclusive; to implement the

project on fast track basis some degree of overlapping is envisaged.

Issuing letter of Indent

Applying to government with all papers for subsidy

Payment from the user to start the project through Bank LC

Procurement of Project Material and transfer them to site

Site preparation including Civil – wherever necessary like mounting on

the roof, support frame to be done by the user as per our directions

Installation of the system at the site

Trial Runs

Training & handing over of the system to the user including system

monitoring.

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PROJECT SCHEDULE

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PROJECT COSTS & COMMERCIAL TERMS

BASIS FOR COST ESTIMATION

The capital cost of the plant has been estimated taking into account

supply of complete system including solar panels, inverters, batteries,

cables, electrical accessories, mounting structure & other equipment

required for the system.

Currently MNRE provides 30% capital subsidy up to 100KW for

installation of solar power systems by commercial organizations.

MNRE Subsidy is available only when Indian made solar panels are used.

The below price is for reputed Indian made solar panels of ISO 9000

standards

Packing, forwarding, inland transportation and insurance for all

equipment and systems including spares have been considered.

Erection, testing and commissioning charges have been included.

Current Applicable Taxes have been included.

Civil works is not considered and is assumed that land or roof is ready for

installing solar panel steel mounting structures.

Power plant life is considered as 25 years.

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GENERAL TERMS AND CONDITIONS

-:GENERAL AND COMMERCIAL TERMS & CONDITIONS:-

Taxes & Duties

Included

Packing:

Prices are inclusive of Packing.

Packing shall be done as per our standard practice.

Freight & Insurance Our offer includes freight and insurance charges.

Validity of Offer:

This offer is valid for 60 days from the date of offer and thereafter subject to our reconfirmation.

Terms of Payment:

1. Letter of intent – to facilitate the government approval which will take around 6 -10 weeks.

2. 75% advance with confirm PO ( as all materials will be Supplied against full payment only)

3. 20% after delivery of materials 4. Balance 5% will be released after 3 weeks of

successful running of the unit.

Delivery period & Installation period

12 -14 weeks after approval from Government

Delivery / Completion

Period:

The Delivery/Completion shall be reasonably extended if:-

- The technical or commercial data required by us to execute the order including advance payment are not made available in time or if subsequent changes, which delay the delivery, are made by the purchaser.

- If the purchaser is behind the schedule with the work he has to carryout or is late in fulfilling the contractual obligations.

Limitation to Liability:

In no event shall we be liable for any consequential damages and/or losses arising out and connected with this supply order in any manner what-so-ever.

Our liability in respect of any defect or failure of the equipment supplied or for any loss, injury, damage

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attributable thereto, is limited to making good by replacing or repairing defects which under proper use appear therein (provided the equipment is installed, operated, maintained as per our instruction manual) and arise solely from faulty design, materials or workmanship within warrantee period. At the termination of which period, all liability on our part shall cease.

Warrantee /

Guarantee:

Solar Module

05 Years Limited Warranty on Product and Workmanship

10 Years Limited Warranty on 90% Power Output

25 Years Limited Warranty on 80% Power Output

For Balance Supplies

12 Months Limited Warranty

Parts and Components, which are repaired or replaced during such period, are warranted for the original warranty period only and will not carry any extended warranty. If the equipment is not repairable at site the same has to be sent at our workshop on freight prepaid basis after obtaining our consent in writing and we shall make good the defect and return back to you on freight to pay basis.

The warranty shall not apply to defects resulting from:

- Willful damage or negligence, normal wear and tear,

- Installation and/or maintenance by Purchaser or a third party without supplier’s

prior written consent,

- Misuse or abuse of Equipment.

- Modifications or alterations made by Purchaser or a third party without supplier's written consent.

Right and Lein of

Property:

We shall retain the right on equipment, materials or parts supplied by us under this quotation until full value thereof as per our invoice has been fully paid to us as per terms and conditions.

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Confidentiality /

Do Not Disclose

(DND):

The information shared by us of any nature during tendering or execution of the contract may be treated truly confidential. Due respect should be taken care to respect the confidentiality of intellectual property. The Confidentiality of this offer should be maintained strictly and in no case without seeking our written permission this document can't be shared, disclosed, reproduced, copied or circulated.

Force Majeure:

We shall be under no liability if performance of contract on our part is prevented or delayed whether in whole or in part due to any of the causes beyond our reasonable control. The supplier shall not be held responsible for any delay, loss or damage arising from any cause, matter or thing beyond the supplier's / sub-supplier's reasonable control, including, without prejudice to strikes, lockouts, go-slow, delays in approval of drawing, rejection of any important part of work, default of sub supplier in supplying the parts / raw materials, lack of transportation facilities, inability to obtain necessary labour or materials, official prohibition of transit of goods,

requisition by legal authorities of personal property, movable or immovable, restriction in power supply or any other action of the government, riots, war or warlike conditions, acts of nature or God such as epidemics, floods, earthquakes, fires etc. whether such delay or impediment occurs before or after the time or extended time for dispatch or completion. In case the supply is affected by the force majeure conditions, we shall intimate the purchaser, within a reasonable time, of such occurrence and suitable extension to the delivery time shall be granted.

OTHER TERMS & CONDITIONS

1. The user will protect the patent right of the unit to the extent possible.

2. Excess material [purchased for the project] will be allowed to be taken back after the project completion

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ABOUT SUN BEST

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.

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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.

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CONCLUSION

This DPR explains in detail the implementation of 100 KW off grid solar power

to assist TTK Prestige to reduce their DG consumption. The solution is

designed to fully replace the 320KVA DG for 290 days a year. Such off grid

solutions have been successfully used in several locations globally and we are

confident of providing a quality solution to TKK Prestige that will give them the

expected benefits.