The pdf explains the steps & quality management procedures to be instituted during Engineering, Procurement & Construction of Solar Rooftop Projects

1. Solar Execution Services
Steps & Quality Assurance for Rooftop Projects

2. Site Survey
Detailed Engineering is completed on the basis of a Detailed Site Survey using tools like measuring tape,
digital distance detector etc.

3. Site Survey
Quality
Shadow casting objects like Parapet wall ,Air Conditioning compressors, Trees, Tower etc., Obstructions
like Water Tanks & Water Pipelines and Location of Termination Point etc is noted carefully to do best
optimized engineering accordingly.

4. Marking
Foundations for the Module Mounting Structures, Inverters, ACDB and other equipment are marked precisely
to avoid any overlap with obstruction or misalignment during construction.
Quality
Foundation to Foundation distance is particularly marked and measured carefully.

5. Foundation Casting & Alignment
Concrete or appropriate grade according to design is mixed and casted with the help of templates of the
desired foundation size.
Quality
Distances between Foundation J Bolts are carefully maintained to avoid misalignment and poor erection of
Structures.

6. Foundation Casting & Alignment
Quality
Uniformity of Height of foundations is ensure using Water Level
7, 14 and 21 days Cube Tests are performed on concrete blocks to ascertain the quality

7. Foundation Casting & Alignment
Quality
Proper Curing of Foundation is essential to ensuring strength in concrete.

8. Unloading of Equipment
Equipment used in a Solar Power Plant, particularly the solar modules are prone to breakage if not handled
with care.
Quality
Unloading on to a flat and obstruction free area using a fork lift or hydra crane should be carried out.

9. Structure Mounting & Alignment
Module Mounting Structures consisting of Legs, Rafters and Purlins are erected and aligned.

10. Structure Mounting & Alignment
Quality
Alignment of erected structures is checked using Water Level.
Proper Tightening of nuts used for assembly needs to be checked.

11. Module Mounting & Alignment
Modules are carefully mounted and aligned on the mounting structures.
Quality
Tightness of Nuts holding the modules to the structures needs to checked. Misplacement and Breakage of
modules is high wind conditions because of improper tightening of modules is not uncommon.

12. Cabling & Conduiting
The Module Strings are connected to inverters, the inverters to ACDBs and the ACDBs to termination point
using Cables which are put inside conduits and cable trays for protection.
Quality
It is to be ensured that conduits laid are straight and without twists or bends.

13. Cabling & Conduiting
Quality
Conduits are sealed using End Caps and PU Foam
Conduits should be placed properly and permanently using clamps and cement where required
Exposed Cables are placed inside flexible conduits.
Tightness of Cables with connectors is checked.
Ferruling at the start and end of cable is done for easy identification in future.

14. Inverter & ACDB Mounting & Cable Termination
Inverters and ACDBs are mounted on Wall or Foundation as the Site Conditions permit

15. Inverter & ACDB Mounting & Cable Termination
Quality
Canopies are provided for ACDB & Inverter if IP65 protection has not been provided by Suppliers
Cable tightness is checked at termination end
Ferruling is carried out for easy cable identification
Body Earthing where required is done for Inverters and ACDB

16. Earthing
Earthing Strips are laid and connected to Structures, Inverters, Lightening Arrestors etc on one side and
Earthing Pits on the other side for protection of all equipment.
Quality
Straightness of laid Earthing Strips
Proper joints between two Earthing strips needs to be ensured with Nuts & Bolts or Welding
Only copper or GI nuts & bolts are used for connecting earthing strips with GI Earthing Rods
Non conducting material, say, rubber is used to separate the overlapped earthing strips

17. Weather Station & Communication Cables
Weather Station for measuring solar radiation, temperature, wind etc. is installed and communication
cables are laid inside conduits to connect all inverters and weather station to a common switch from where
the radiation and generation related data can be sent.
Quality
Spacing is maintained between communication cable & Power cables to avoid interference
RS45 Connectors are tightened properly for long term connectivity & to avoid data interruption

18. Finishing & Touchup
Finishing and Touchup Work like whitewashing of foundations and tying of loose cables is concluded before
system is commissioned.

19. Commissioning
The Plant is commissioned and the inverters synced with the Grid Current to give seamless electricity
to the available Electrical Load.

20. Experience Snapshot
200 kW, IIT Kanpur, Uttar Pradesh
200 kW, VIT Andhra Pradesh 130 kW, NIMS Hospital, Kerala 100 kW, VVIT, Andhra Pradesh
100 kW, NCET Karnataka 5 kW, Raheja Residence, Delhi 1 kW, 70 systems, Kerala

21. About Gensol
Gensol Consultants, found in 2007 is India’s leading Advisory and System
Integrator for Solar PV Power Projects. Gensol is a channel partner to MNRE and
enjoys empanelment with most major Lending Institutions in India.
1,000+ MW 1,000+ kW
Gensol has an advisory portfolio of
more than 1 GW with every 5th MW in
India developed with our expertise.
Being an MNRE Channel partner,
Gensol has executed more than 1
MW of Solar Rooftop Projects across
India.
Gensol is based out of Ahmedabad in
Gujarat but has operational solar
projects across 16 Indian States.
With a 30+ Employee Strength –
Gensol prides itself on having the
best technical talent in industry.
AWARDS
BusinessWorld – India’s largest
weekly business magazine awarded
Gensol with “Hottest Young
Entrepreneur” in 2009.
Economic Times – India’s largest
financial daily awarded Gensol in its
“Power of Ideas” series in 2010.
Gensol was the only non-UK based
firm to be nominated for Global
Consultancy of the Year at
BusinessGreen Leader Awards,
London in 2014.

22. Solar Advisory & EPC Services
Owner’s Engineer:
As Owner's Engineer, we guide our clients or investors through the complete process of project feasibility, financial closure, bid process
management, vendor finalization and supervision of project execution up till successful project commissioning which meets our strict
quality criteria.
Lender’s Engineer:
Being consultants to some of the leading lending institutions in the country, we assess the key parameters impacting the returns from the
project like generation, cost and conditions of the EPC Contract, preparedness of Project Developer for execution etc.
Detailed Engineering and Vetting of Drawings:
Gensol Solar Division is staffed with experienced Electrical, Electronics, Mechanical and Civil Engineers who undertake detailed
engineering of Solar PV Power plants on behalf of EPC Contractors and vetting of drawings for Project Developers and investors.
Permits & Clearances:
It takes more than 32 permits and clearances from Nodal Agencies, District Authorities, Distribution and Transmission Companies etc.
Gensol has an experienced liasoning team well aware of process and people to acquire these permits in time and in sequence.
Detailed Project Report:
A Detailed Project Report is one of the most important documents to assess the feasibility of project and to get financial closure. Gensol
with its sector expertise and established standing in the renewable energy consultancy not only gives the most exhaustive analysis of the
project but also enjoys the confidence of industries, investors and banks alike.
Solar EPC Services
Gensol, being a channel partner of Ministry of New and Renewable Energy (MNRE) has attained amongst the highest
allocation of subsidies for the Solar Rooftop Projects on account of its superior engineering, standardized procurement and
quick execution. Gensol has executed projects in the range of 1 kW powerpacks to 400 kW single rooftop power plants.

23. Gensol Engineering Pvt Ltd | Gensol Consultants Pvt Ltd
Corporate Office
108, Pinnacle Business Park
Opp Royal Arcade, Prahladnagar
Ahmedabad, Gujarat
India - 380015
Email: solar@gensol.in
Website: www.gensol.in
Phone: +91 79 40068235
Fax: +91 79 40068239
Twitter: gensol_tweets
Gensol is one of the leading consultants and system integrators for Solar Power Plants. We boast of a portfolio of over 800
MW of Solar Photovoltaic Plants. Gensol is also a channel partner to Ministry of New & Renewable Energy and installs
kW scale Solar Rooftop systems on a turnkey basis with more than 1 MW of cumulative installations across the country.
The information contained herein is of a general nature and is not intended to address the circumstances of any particular
individual or entity. Although we endeavor to provide accurate and timely information, there can be no guarantee that such
information is accurate as of the date it is received or that it will continue to be accurate in the future. No one should act on
such information without appropriate professional advice after a thorough examination of the particular situation.