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Manufacturing Factory Grid–Diesel–PV Cost Reduction & Power System Analysis

Independent engineering study for a manufacturing facility combining an 8,760-hour load and dispatch model, rooftop PV sizing and energy-yield simulation, and ETAP power-system studies for grid, diesel and PV operating scenarios.

Engineering Scope

Technical work and responsibilities

  • Cleaned and structured an 8,760-hour annual load profile in Python, including grid-availability status and baseline grid/diesel dispatch.

  • Compared six PV capacities from 1.198 MWp to 2.874 MWp to assess solar utilisation, curtailment, diesel displacement and operating-cost savings.

  • Modelled the 2.874 MWp maximum-roof, zero-export PV scenario in PVsyst using 5,423 × 530 Wp modules and 22 × 100 kW inverters.

  • Developed the grid/diesel/PV electrical network in ETAP and evaluated load flow and time-series load-flow operating conditions.

  • Performed IEC 60909 three-phase short-circuit analysis and reviewed fault levels across the LV and 11 kV buses.

  • Completed an IEEE Std 80 ground-grid study to assess grounding arrangement, touch potential and step potential.

Delivery Outcomes

Verified project results

  • Modelled annual facility demand of 9,014.4 MWh from a complete 8,760-hour dataset, with 4,380 grid-available and 4,380 grid-unavailable hours.

  • PVsyst simulated 4,333.2 MWh/year of solar energy supplied to the load, 1,508 kWh/kWp/year specific production, 67.45% performance ratio and 48.07% solar fraction.

  • Python scenario analysis estimated a 74.4% reduction in baseline diesel-generator energy for the 2.874 MWp case, equivalent to about 1.17 million litres/year of diesel avoided under the study assumptions.

  • ETAP time-series results confirmed acceptable operating-voltage behaviour in the assessed scenario, while short-circuit and grounding studies provided fault-duty and electrical-safety checks for the modelled system.

Technical Areas

Engineering methods and project disciplines

PythonExcelPVsystETAP
Industrial EnergyGrid-Diesel-PV8760 Load ProfileZero ExportPVsystETAPLoad FlowTime-Series Load FlowShort CircuitGround Grid

Selected project evidence

Engineering Drawings

2 items

PDF

Engineering Drawings

ETAP Time-Series Load-Flow One-Line Diagram PDF

Original ETAP one-line drawing for the modelled grid, diesel, PV and factory-load system.

Sep 2026

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Reports / PDFs

3 items

PDF

Reports / PDFs

PVsyst 2.874 MWp Zero-Export Simulation Report

PVsyst simulation report covering system configuration, annual energy results, losses and financial outputs.

Sep 2026

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PDF

Reports / PDFs

ETAP IEC 60909 Fault Study Report

ETAP report covering three-phase fault-current results for the modelled LV and 11 kV buses.

Sep 2026

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PDF

Reports / PDFs

ETAP IEEE 80 Ground-Grid Study

Ground-grid report documenting the modelled conductor and rod arrangement with touch- and step-potential checks.

Aug 2026

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