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PROPOSAL FOR A PHOTOVOLTAIC PANEL PRODUCTION LINE 25 MW X 4 PLANT

PROPOSAL FOR A PHOTOVOLTAIC PANEL PRODUCTION LINE

25 MW X 4 PLANT KRV is a company with a vision to use and implement renewable energy

technology for generating Solar Power for commercial purpose. Our main focus areas are selling of PV (photo voltaic) panel manufacturing plant. The mission of the company is to make more affordable solar system for a better future of our planet.

We were doing Research from last couple of years and now we have brought it from laboratory to market ready products and advanced it in to series production. We offer complete turnkey solutions for our products. We are having team of experts who have been educated from well known education institute and having very good hands on experience of solar industry. We have strong relationship with many research institutes across the globe for developing efficient solar panel for generating maximum solar power.

Our groups are in the business of solar module manufacturing, laser, textile, waste recycling and solar module manufacturing equipment.

Renewable energy is the emerging sector. Because of global warming effect, high price of crude and economic recession, world is in a search of clean alternate source of energy. We strongly believe that renewable energy is the next revolution after semiconductor and computer business. Solar is the most aggressive energy in all the renewable sources of energy.

Approximately 0.1% of the world's area utilized by solar photovoltaic plants would be sufficient to generate the world's entire electricity demand. Global PV market has continued to grow at outstanding rates. Production of PV is growing at over 30% annually.

Today most of the developed and developing countries have introduced solar incentive policy. Indian government is promoting production of Solar Power. Indian government introduced ‘NATIONAL SOLAR MISSION’, in which government targeted 20000 Mw of installed solar generation capacity by 2020 and 100,000Mw by 2030.

All state government in India is also introducing their own solar policy too. We strongly believe that solar technology is the most emerging technology among all renewable energy technologies. Sun is an infinite source of energy for our earth.

PV MODULES:-

Flat-plate photovoltaic collectors contain an array of individual photovoltaic cells, connected in a series/parallel

circuit,and

encapsulated within a sandwich structure with the front surface being glass or plastic. Solar energy falls directly upon the photovoltaic cell frontsurface and produces a small direct current voltage, providing electrical energy to a load.

Like flat-plate photovoltaic collectors (panels) absorb both energy coming directly from the sun's disc, and diffuse and reflected energy coming from other directions. In general, flat-plate photovoltaic panels are mounted in a fixed position and tilted toward the south to optimize noontime and daily energy production. However, it is common to see flat- plate photovoltaic panels mounted on mechanisms that track the sun about one tilted axis, thereby increasing the daily output of the panels.PROJECT DETAIL:

We are pleased to offer you our solution for producing photovoltaic panels with an output of 25MW/YEAR from 3 shifts, 350 Days. We are also listing the material and service required in order to start up production on the plant on a turnkey basis.The line 25 MW includes the following items:1. Production equipments.2. Technology of the PV process & Complete Raw Material Techno commercial Help3. Special lay out for your factory4. Set up and installation in the customer facility5. Transfer of know-how with the training in your site.6. Demonstration runs of the module production cycle7. Comprehensive spare parts kit.8. One year equipment warranty.

9. Assistance for IEC 61215, safety standard 61730 and MNRE Certificates

THE PV MODULE PRODUCTION PROCESS:

The PV Production Process uses solar cells and module materials as input and produces functional PV modules, ready for use. The Process consists of the following phases:

Cutting EVA and placing it on the glass substrate, using the Film Cutting Machine Assembling and soldering strings of cells interconnected with metal ribbons

using the Tabber & Stringer. Strings can be unloaded on the Lighting Table for the visual inspection or placed directly on EVA on glass.

Aligning and placing strings on EVA on glass thanks to the Lay out Machine (option of the Tabber & Stringer)

Completing the module laminate circuit by soldering bus ribbons to connect the strings together and provide output leads at the busing station.

Visually inspecting and electrically testing the module laminate circuit by measuring its dark I-V characteristics at the inspection station.

Cutting EVA and back sheets to length and assembling them with the glass and cells circuit, in preparation for the encapsulation.

Laminating the sandwich and curing the EVA with the Laminator. Completing final assembly, which includes edge trimming at the Trimming

station, installing and edge gasket and frame with the Frame Assembly and attaching a junction box at the JB station.

Performing a high voltage isolation test to measure the voltage isolation between the cells circuit and the module frame, and testing the frame ground continuity.

Electrically testing the module under simulated sunlight with the Solar Simulator to measure its performance.

Visually inspecting the completed module for quality of materials and workmanship.

SOLAR PANEL LAYER AND STRUCTURE:

THE COMPONENTS:1- GLASS 2- EVATempered, with high transitivity. (Ethylene Vinyl Acetate) Encapsulating material.

3- CELLS 4- TEDLAR/BACK SHEETPolycrystalline cells connected in series, Texturized for better exploitation of the radiation.

5- JUNCTION BOXIt provides a simple means for making the electrical connection between the module and the rest of the plant.

\Solar

Cells

Lay Out Station Strings Inspection

Cell Testing

RibbonAnd Flux

InfraredSoldering

onnectin CellsgcInter

Tempered Low-Iron Glass WashingGlass Station

Film CuttingStation

Bus RibbonsStation

EVA only

Lamination

Framing StationH. Voltage &BoxGround Test

Trimming & JB Station

Module Inspection

FLOW CHART OF PRODUCTION LINE:-

Frames

Junction

EVA and Back sheet

TECHNICAL DATA REQUIRE:Power requirement 100 KWMin. Ambient Temp. 20 CMax. Ambient Temp. 35 CHumidity: 80%

STANDARD DATA FOR WORK ZONE:Building area 25000 square feet

EXCLUSION:Clean room and conditioning systemsLocation waterCivil and building worksGenerator for power emergencyCranes and lifting equipmentsStorage, handling and transportation of the equipment at siteAccommodation and food for engineers during installation period.

EXCLUSION FROM EQUIPMENTS:

Air Compressor and Moisture Separator.Drill machine, Cutter Machine, Grinder Machine, Hydraulic Pallet.Chain Pulley, Tool Kits.Fan for laminators exhaust, Oil Pumps and water pump.

General Sales And Conditions

1. INSURANCE : Complete insurance from buyer end.

2. PACKAGING : Included.

3. TESTING: The system will be tested at customer premises.

4. INSTALLATION: The installation of the machine will be done on customerpremises by our technicians. Installation charges are included in plant cost.Accommodation and food are provided by customer.

The installation of the machine must be strictly within 20 days from delivery.

5. SERVICE SUPPORT: We provide one year free service support to the customer.After one year we will work on AMC base.

6. WARRANTY : 13 months on all component of plant from the date of themachine shipping or 12 Months from installation date whichever is earlier.

7. DOCUMENT S :

Certificate installation and final test signed by your technicians.

Maintenance and spare parts manual. Wiring diagram manual.

TRANSFUSION IN CONTRACT:

This proposal, if accepted by the parties must be transfused into a detailed sales contract to be signed between the legal representatives of the contractors. We hope the above proves of interest and we remain available if you require any further information.

Thanks you in advance.

Best regards,NIRALA ENGINEERING

Product Line Needs The Following Machine And Equipments:-

Sr.No.

Machinery Name 25x4mw = 100 MW

1 Automatic Laminator 12 Glass Washing Machine 13 Solar Cell Tester 14 Solar Module Tester 15 Framing Machine 16 Aluminum Frame Cutting Machine 17 Aluminum Frame Punching Machine 18 Cell Soldering Table 29 Laser Dicing Machine 110 EVA, TPT Cutting Table 111 Lay up Table 312 Module Transfer Carrier 313 Ready Material Carrier 314 Assembling Table 215 Appearance Inspection Table 116 Soldering Ribbon Cutting Machine 117 Electrical Iron 818 Pneumatic Glue Gun 119 EL Tester 120 Tabber and Stringer - KRV 1300C 1

1 - AUTOMATIC LAMINATOR

ParametersPower supply 65 kW, 380 VAC, 3-phase 5-wireHeating medium OilTemperature range 30 to 160 ℃, controlled by Intelligent PLCTemperature uniformity +/- 2 ℃ Pumping Speed 70 L/s, reaching 100 Pa within 2 min;Air Supply 0.4 to 0.8 MPa, max 0.8 m³/minMax module thickness 25 mm

Outstanding Features

Auto loading, unloading part with cooling fan.Cover is lifted vertically, with auto self cleaning function. Silicone rubber sheet is fixed by easy hooks.Oil pipe are protected with insulation measure to reduce energy consumption. Temperature measuring points are displayed on the touching screen.vacuum meters are installed to ensure the vacuum value being seen. Various alarming sub-system for oil, vacuum, temperature, safety etc.

Major components

1 AC Connector: Schneider: LC1

SERIES 2 PLC Controller:

Schneider

3 Module : Schneider : EM331

EM323 4 Touching Screen :

Schneider

5Electro-magnet Valve : SMC

6 Pneumatic Valve : Flowx Italian

7Heating System :Fuxin Hongda

QXD-42 8 Vacuum Pump : Huaxin

Nanguang 2X-70

9 Digital Pressure : Sensor SMC ZSE30 Aseries

ISE30A 10 Silicon Sheet : Keqiang

4120X2720X4

11 Teflon Sheet - Thickness 0.35mm

12 Temperature Test Pole Platinum Resistance PT100

2 - GLASS WASHING MACHINE

Input power: 420V Working speed: 2m/min Minimum length of glass: 200 mm Maximum width of glass: 1200mm Thickness of glass: 1.8-8mm Dimensions: 2500*1600*900 mm Brush: 2 pairs Air knife: two tricks Cycle water tank, replace water once a day, use 0.2 CBM water per tank.

3 - SOLAR CELL TESTER

Solar Cell Tester for 156 X 156 mm Cell. Light Source

Light uniformity: < ± 3% Intensity Instability: < ± 0.5%Intensity section range: 30 ~ 120 mW/Cm2 Pulsed xenon lamp life: 1,00,000 Times

Electrical Measurement Measurement Range: Voltage: 0 ~ 0.8V, current: 0 ~ 12A Data Collection : 3 to 5 ms

Repeatable test results : < ± 0.5% Work

Single flash automatically measure IV curve and the fixed voltage and current Data acquisition time: < 4msShortest test interval: 3s

Overall dimensions: 38cm × 49cm × 70cm Power Supply: 220V ± 10% 5A , 50 Hz Applied for solar cell testing & sorting

4 - SOLAR MODULE TESTER

Maximum Test area: 2000*1100. Light Source

Light uniformity: < ± 3% Intensity Instability: < ± 0.5%Intensity section range: 500 ~ 1250W/m2Pulsed xenon lamp lifetime: > 1,00,000 times ( Xenon Lamp is from Germany)

Electrical Measurement Measurement Range: Voltage: 0 ~ 100V, current: 0 ~ 20A

Repeatable test results: <± 0.5% Work Measures the following parameters: I-V curve, Open circuit voltage (Voc), Short-

circuit current (ISC), Peak power (PM), Current and voltage at peak power (IM and VM), Fill factor (F.F.), Module efficiency (Eff.), Module temperature (Temp).

Single flash automatically measure IV curve and the fixed voltage and currentData acquisition time: <± 2ms. Shortest test interval: 9s, Power Supply: 220V ± 10% 5A.

5 - FRAMMING MACHINE

Solar Panel Minimum size 350 * 600 *50 (35) mm Solar Panel maximum size 1100 *2000 * 50 (35) mm Source of compressed air cylinders volume: air Source: 0.6 ~ 0.8 MPA; Rated pressure: 8.0 Kg/cm Power: AC 220V/50 Hz Weight ：1050 KG Application of aluminium frame 35mm or 50mm The group frame, rivets in an integral whole Strong point, the width dimension are pole less adjustable Distinctive allocation is locked up. The multiple spot assists pressure the

head handle simple, nimble, convenient

6 - ALUMINUM FRAME CUTTING MACHINE

7 - ALUMINUM PUNCHING MACHINE

Power Supply: 440V / 50Hz or according customers require.

Input Power : 3.6KW Working Air Pressure :

0.5- 0.8MPa Blade Rotational Speed

: 3087r/min

Saw Blade Specification : D=450mm,

Cutting Length : 580-3700mm Cutting Angles : -45° -90° -45° Outside Dimension :

4500*1100*1400mm

Weight (about) : 1250Kg

Maximum punching force:

20KN Punching stroke: 30mm

Air pressure: 6-8Kg/cm2

Maximum ceiling height: Max150mm

Dimensions: 4500mm × 500mm × 1700mm

8 - CELL SOLDERING TABLE

9 - LAY UP TABLE

Worktable: 1200mm * 1800mm * 1000mm.

Single soldering heating plate 2 PCS

Series soldering heating plate 1 PCS

Soldering controller 2 PCS

Serial soldering mould 1 PCS

Aluminum Tray 2 PCS

It includes the inspection lamp and electrical meter.

10 – LASER DICING MACHINE ( Fiber)

The 20 W fiber laser with optics isolation system has high stability and good scribing quality,

better than traditional lamp-pumped laser. Its 1,064 nm laser wavelength could scribe on

silicon wafer/ solar cell/ ceramic wafer/ thin metal sheet.

● Great laser quality/ reliability● Very Low operation cost● Maintenance-free● Air cooling system● Compact design● Easy operation and professional software

Technical Specification

Laser: 1, 064 nm, Max 20 W, air- cooled

Min line width: 0.02 mm

Max cutting depth: 0.2

mm

Min laser beam diameter: 0.02mm

Max scribing speed: max 200 mm/s

Power supply: AC 220V +/- 10%,

50Hz Input power: 1 kW

11 – ASSEMBLING TABLE

12 - EVA CUTTING MACHINE

Provide horizontal surface to lay up the solar cell string, stack the solar cell string, temper glass, EVA & back sheet and wire the solar cell string with ribbon.

EVA Cutter is an semi-auto EVA and Toddler cutter with the auto press

panel. Cutting Size: 1200mm x 2000mmCutting Thickness: 8mm

13- MODULE TRANSFER CARRIER

Hand truck for transportation of Glass/ Solar modules / Panel at different stage of production. The module carrier made of steel and continues welding with rubber combination.

It should carry 10 sets of 240W solar panels at one time & strong mobile castors for free and smooth movement during transport of modules / panels.

The wheels can be locked for safety and stability to avoid any accidental damage.

14 - READY MATERIAL CARRIER

15 - APPEARANCE INSPECTION TABLE

16 – SOLDERING RIBBON CUTTING MACHINE

Provide horizontal surface to lay up the solar cell string, stack the solar cell string, temper glass, EVA & back sheet and wire the solar cell string with ribbon.

Support 300 W modules.

Inspection of the finished layup solar module before laminating.

Inspect the items such as if the solar cell be broken, also the quality of lying up.

The station with the observation mirror and light. Support 300W panel.

Automatic cut the soldering machine after set the length, speed, quantity number.

The machine can levelling the ribbon, so can improve the quality of soldering.

17 – ELECTRICAL IRON

18 – PNEUMATIC GLUE GUN

Heating by high frequency vortex, special sensor can accurately rapid control iron the soldering temperature? Up temperature and down temperature is fast.

Power: 150WTemperature: 100°C - 500°C Temperature stability: ±2 Dormant time: 0~99min Stop time: 0~99minSize: 96(W)×160(D)×135(H) mm

Gluing the gel for the framer and junction box by the compressed air.

Glue the gel high–speed and even.

19 – EL Tester

Module Type Module type: Mono-/ Poly- crystalline PV moduleModule size: 2000 x 1100 mmImage Sensor Nikon, NIR, industrial gradeExposure: 0.1 to 60 s, adjustableMax current, Voltage:

10 A , 60V

Normal Cycle Time 45S Per ModulePower Supply 220V , 10 Amp , 1 KWCompressed Air 1 m3/hEnvironment Temperature 10 to 30 deg C, RH 20% to 70%Defects detectable: Soldering defects/ firing defects/ material defects/ micro cracks/ surface

contamination/ busbar broken/ current mismatch/ dark areas, ...

20-Tabber and Stringer- KRV 1300C

1. KRV-1300C tabber stringer is the first machine in China, which is compatible with soldering of cut cell with min. width of 31.2mm and full cell. Customers have more options with only 1 machine.

2. Automatic drying function by using waste heat, which is energy saving and environmental protection, can avoid the flux contamination to cells.

3. Ribbon automatic bending and cutting function, which is able to reduce the cells breakage caused by distance between solar cells.

4. Adopts the most popular non-contact infrared light soldering method, which ensures cell and ribbon be uniformly heated to reduce the rate of breakage.

5. With multiple temperature zones, slow warming and slow cooling reduce rate of breakage.

6. Compatible with 125mm and 156mm cell. Fine-tuning function, which is easy and timesaving to switch between 2, 3, 4 and 5 bus bars. Switch between different width cells with same bus bar within 30 minutes.

Technical Data:

Production capacity 1,150cell/hour for full cell, 1,000cell/hour for cut cell

Breakage rate ≤0.2% A grade cell

Welding method Infrared light

Applicability

Polycrystal Monocrystal

156mm*156mm 2BB (Width 31.2mm-156mm)

156mm*156mm 3BB (Width 31.2mm-156mm)

156mm*156mm 4BB (Width 31.2mm-156mm)

156mm*156mm 5BB (Width 31.2mm-156mm)

125mm*125mm 2BB

Distance between cells 1mm-10mm Adjustable

Cell thickness 150 m-280 mμ μ

Ribbon SupplyStraightening, bending , cutting and positioning automatically by Servo motor

Max welding length 2000mm

Cells transmission mode Imported TEFLON belt driven

Electric system PLC+ Servo Control System

HMI Touch-screen, simple operation

Fault Alarm Real-time alarm

Working temperature 5℃-35℃

Power Supply Three-phase Supply 380V±5% 50Hz 50A

Compressed air Air pressure: 0.5—0.8MPa Air flow: 0.5m3/min

Power Max 18KW Ave 9.5KW

Dimension 5700mm*1300mm*2000mm

Weight 1600kg

*5BB is optional.

Production DataProduction of 250 Watt Panel

PRODUCTION ( 250W Panel)

1 Hour : 250W X 12 Panel = 3KW

1 Day = 24 Hr X 3 KW = 72 KW

1 Year = 350 Days X 72 KW = 25.2 MW

This data will be Multiply by 4 times