5500 KW Solar Project for Sanvijay Rolling Nagpur
When most EPC companies saw the site, they saw a problem. We saw a challenge worth solving.
At Sanvijay Rolling Mill, a leading metal rolling industry, the environment was tough—constant heavy dust, high-temperature operations, and a rooftop exposed to continuous industrial activity.
The biggest concern wasn’t just installation—it was performance.
Dust accumulation posed a serious risk to solar generation, and many believed that installing a reliable rooftop solar system in a rolling mill environment would be extremely difficult.
In fact, several EPC companies visited the site, assessed the conditions, and stepped back.
Some even concluded that proper solar installation in a rolling mill environment was not practical, warning that performance and long-term reliability would be compromised.
But at Chirayu Power Pvt. Ltd., we saw things differently.
Instead of avoiding the challenge, we chose to accept it.
Our team carefully studied the site conditions and designed a solution tailored specifically for a dust-heavy industrial environment. To ensure safety, reliability, and optimized generation, we initiated the rooftop solar project using advanced SolarEdge Technology, enabling better monitoring and improved performance even under challenging site conditions.
That moment marked the beginning of a project many believed couldn’t be done—
but one that would soon prove otherwise.
Project Overview: Engineering Solar in a High-Dust Rolling Mill Environment
After accepting the challenge at Sanvijay Rolling Mill, the next step was to design a system that could perform reliably despite extreme dust conditions while ensuring maximum generation and long-term safety.
The project was executed using high-efficiency Rayzon Solar modules, featuring 580/590 Wp Mono PERC Half-Cut Bifacial (N-Type) technology, ensuring better performance even in diffused light and harsh industrial conditions.
System Configuration & Technology
To tackle generation concerns and ensure module-level performance tracking, the plant was designed using SolarEdge Technology:
- Inverter Capacity: 100 kVA × 42 Nos. + 33 kVA × 1
- Optimization System: Module-level DC optimization
- Warranty:
- Inverter: 12 Years
- Optimizers: 25 Years
Each optimizer supports 2 solar panels, allowing better generation even if some modules are affected by dust or shading.
Customized Structure Design for Industrial Conditions
Understanding the complex rooftop structure and dust-prone environment, a site-specific mounting strategy was implemented:
- Short Rail Structures (Mono Rail): Designed as per roof slope
- Elevated Panels: Raised by 1 meter on north side for better airflow and reduced dust impact
- Tilt Optimization: South tilt ensured for maximum solar exposure
- Special Long Rail Structure (B2R Area): Installed carefully to protect cement sheet roofing
This ensured both structural safety and optimized energy generation.
Maintenance-Focused Design
Since dust was the biggest challenge, the system was designed keeping easy maintenance access in mind:
- GI Walkways (300mm): Installed across the plant for safe and regular cleaning
- Strategic placement ensures quick accessibility without damaging modules
Electrical & Safety Infrastructure
A strong electrical backbone was installed to ensure safety and efficiency:
- Advanced Combiner Boxes: With MCCB, SPD, phase indicators, and IP65 protection
- Generation Meter: CT-operated multifunction meter for accurate tracking
- Heavy-Duty Cabling:
- DC: KEI 4/6 sq.mm double insulated
- AC: Up to 300 sq.mm aluminum armored cables
Robust Earthing & Lightning Protection
Given the industrial setup, safety was a top priority:
- Earthing System:
- Pure copper bonded chemical earthing (3m rods)
- Total Earthing Points: 30 Nos.
- Lightning Arrestors:
- ESE Type with 100m protection radius
- Total Installed: 7 Nos.
- Earthing Conductors: BIS-approved heavy-duty strips and cables
Smart Monitoring System
The plant is equipped with real-time monitoring:
- Panel-level, inverter-level, and system-level tracking
- Accessible via mobile app and web platform
- Helps in identifying performance drops due to dust instantly
Performance Output
Despite initial concerns about dust affecting efficiency, the system delivered strong results:
- Expected Generation: 1460 units/kW/year
- Total Annual Generation: 87,60,000 Units
Before vs After: Measurable Impact
Before Solar Installation
At Sanvijay Rolling Mill, operations were heavily dependent on conventional grid electricity, leading to:
- High and fluctuating electricity costs
- Increased operational expenses due to energy-intensive rolling processes
- Zero control over power cost escalation
- Significant carbon emissions from non-renewable energy sources
After Solar Installation by Chirayu Power Pvt. Ltd.
With the successful commissioning of the rooftop solar plant, the transformation was immediate and measurable:
Energy Generation
- Annual Solar Generation: 87,60,000 Units
- Specific Generation: 1460 units/kW/year
Cost Savings
- Approx. ₹6.5 – ₹7.5 Crore annual electricity savings (depending on tariff)
- Reduced dependency on grid power
- Protection against rising electricity costs
Environmental Impact
- Approx. 6,500 – 7,000 tons of CO₂ emissions reduced every year
- Equivalent to planting 3+ lakh trees annually
- Supporting clean and sustainable industrial operations
Operational Benefits
- Improved energy reliability for continuous rolling operations
- Optimized performance even in dust-heavy conditions using advanced technology
- Reduced maintenance downtime with planned accessibility (GI walkways)
Conclusion Transition
What started as a “high-risk project” in a dust-heavy rolling mill environment turned into a benchmark installation—proving that with the right technology and engineering, even the toughest industrial sites can achieve reliable solar generation.
