Solar Panel Installation: Step-by-Step Guide

As an Installer/EPC company, youare likely familiar with the process of installing a solar plant. In this blog, we will not be detailing the installation procedures but rather outlining key processes that can serve as a checklist for your next project. If you are just beginning your journey as an EPC company, this information will help you plan your installation effectively, enabling you to avoid mistakes and delays while successfully installing a solar plant.

While every solar plant is unique as every building is unique, but if you follow certain procedures and standards, it becomes a like an assembly line where you just do things back-to-back.[TG1] 

Before getting into the blog, here are some documents that you should be ready with as an installer/EPC to make the journey easier.

• Site Survey Form
• Template for quotation
• SOP for Installation and Commissioning
• Operations and Maintenance Checklist

The above documents can be prepared internally or here are some documents from MNRE that can help you create your own version of the document.

Now let us understand the step-by-step procedure with an example throughout this blog.

1. Feasibility and System Capacity

• Before conducting a site survey for feasibility, it is important to analyze the customer requirements over a call and get the electricity bills and location. This will help understand the capacity requirement and the irradiation, rooftop area, and shadow conditions roughly. 
• Once you arrive at the capacity, it becomes easier to figure out costing and quotation.
• This will happen in two ways, first by analyzing their electricity bills for the last12 months to arrive at the required solar capacity to reduce the electricity to the fullest.
• Secondly, a site survey is required to understand what capacity can be realistically accommodated on the roof. You can find how to do a detailed site assessment in one of our previous blogs here. Based on the lowest capacity that you arrive from the above two processes.

2. Design and Sizing

Once you arrive at the system capacity, choosing the rating of the solar panels and inverter can be done immediately.  If you have space constraints then you can recommend a highest rating panel available in the market. In most cases, it always makes sense to go for a higher capacity of solar plant considering the increasing electricity tariff.

If the capacity is higher, it is recommended to check with the solar panel supplier and inverter for availability, if the rating of solar panels or inverters as per the design is not available, then you might have to redesign as per the availability.[TG3] 

3. Permits and Approvals

It is important to start the government approvals once you have closed the deal with your client. Start the registration process with the DISCOM for Net metering. Net Metering process has to be done simultaneously to ensure that it is done on time and the consumer can get the benefits of the solar as early as possible.

Also, if the site is residential ,it is most likely that your client is eligible for the PM Surya Ghar Muft Bijli Yojana through which the client can claim subsidy. If eligible, you can get the client registered on the National Solar Portal.

It is always advised to initiate Government processes early on and follow the procedure timely without any delay.

4. Procurement of Materials

It is very important to plan your procurement well in advance. Like checking the availability and prices of materials especially solar panels and inverter as they take up most of the cost of inverter and in order to avoid any delay in the installation process.

Bill of Materials forms the most important document post designing. It is important to prioritize the following things:

• High ticket items like solar panels and inverters
• Module mounting structure if it is customized and or elevated.
• Material/items that have longer delivery timeline/is not available off the shelf/procured from a distant location/vendor to save on cost.

It is also critical to ask for test reports and photos of material before dispatch. Also, it is advisable to strategize favourable payment terms considering even the client won’t be paying the entire amount at once.

5. Installation

In case of sloped roofs, safety lines need to be installed first and foremost. It ensures that safe working condition for your installation team.

The next thing would be clearing out any debris or things kept and figure out power supply and water to start the installation.

The installation procedure includes following steps:

1. Installation of PV array mounting structure
2. Installation and testing of structure earthing system
3. Installation of PV modules
4. Earthing of PV module frames
5. DC cabling and installation of DCDB
6. AC cabling and installation of ACDB and inverter
7. System protection and safety – Earthing, Lightning Arrestor
8. Remote Monitoring system installation
9. Placing of signages and labels.

6. Testing and Commissioning

Once the installation is complete, it’s important to test the system to ensure everything works as it should and it is safe to commission the system.

• Pre-commissioning tests including checking voltage and current of the system.
• Commissioning the system
• Anti-Islanding functionality test
• Net Metering – This will also involve the DISCOM authorities to visit the site and approve the net meter installation.

7. Maintenance and Monitoring

Remote Monitoring system: Once you configure and connect the remote monitoring system/inverter-based system, it is essential that you provide a demonstration of the mobile application, website and share login credentials with the client.

Panel Cleaning: Although solar panels do not require regular cleaning, dust can accumulate over time, leading to reduced efficiency. Provide clients with tips on safely cleaning their panels or offer professional cleaning services.

Warranties and Aftercare: As an EPC company, it is essential to offer warranties to the rooftop solar plant and inform the client on the same. Additionally, ensure that clients knowhow to contact you for any future support or troubleshooting needs.

8. Conclusion

As a professional solar EPC company, your role is crucial in ensuring that rooftop solar plant is installed correctly and has provides optimal generation. This blog gives a brief understanding and few tips to ensure your next installation is efficient and smooth.