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3m SPV Plant
3m SPV Plant
INSTITUTE OF SCIENCE
3-MW scale
grid-connected solar
photovoltaic power plant
at Kolar, Karnataka
Performance assessment &
recommendations
H. Mitavachan, Anandhi Gokhale
and J. Srinivasan
REPORT IISc-DCCC 11 RE 1 AUGUST 2011
INDIAN
INSTITUTE OF SCIENCE
3-MW scale
grid-connected solar
photovoltaic power plant
at Kolar, Karnataka
Performance assessment &
recommendations
H. Mitavachan, Anandhi Gokhale
and J. Srinivasan
REPORT IISc-DCCC 11 RE 1 AUGUST 2011
Executive Summary
Karnataka Power Corporation Limited (KPCL) has established 3 MWpeak capacity
grid-connected solar photovoltaic power plant near Yalesandra village in Kolar
district of Karnataka, which is the first of its scale in India. After the site
preparations were completed the first segment was installed in 4 months,
followed by the second and third segments in the next two months. The plant
was fully commissioned on 27 December 2009. The Yalesandra plant is one
among 20 such Mega-watt size solar power plants in India, *as on 31st July
2011. India has an ambitious plan to build large grid-connected solar power
plants, with a cumulative installed capacity of 20,000 MWp by 2020, under the
National Solar Mission. Hence, it is essential to document the performance of
the first large-scale grid-connected solar power plant installed in Karnataka. In
this report we discuss the performance of the photovoltaic solar power plant in
Kolar during 2010.
0
Contents
1.
Introduction
2.
Site details
3.
Performance Analysis
10
17
18
19
20
4.
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5.
Conclusion
25
6.
References
26
7.
Acknowledgments
27
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1. Introduction
Karnataka's power sector has three main
utilities namely; Karnataka Power
Corporation Ltd. (KPCL) - the Public Sector
generation utility, the Karnataka Power
Transmission Corporation Ltd. (KPTCL) the Public Sector transmission utility, and its
regional distribution utilities - Electricity
Supply Companies (ESCOMs). KPCL is the
main power generator in the state with an
installed capacity of 5975.91 MW of hydel,
thermal, solar and wind energy, with an
additional 9500 MW in the pipeline.
Till 1985, the state's entire capacity had
been hydroelectric, but with 2328 MW of
coal based thermal power stations (and a
few diesel and wind-based plants), the hydro
share of capacity has dropped to about 61%.
Further, only about 75% of the hydro
capacity is available for utilization; the
remaining 25% comprises (a) non-firm
capacity (i.e. a part of the water stored in
some hydro-reservoirs is also meant for
irrigation), (b) unforeseen outages
(necessitating a spinning reserve), and (c)
maintenance protection reserve. Also, in
years of poor rainfall, the contribution of
hydel plants to annual electricity generation
decreases further [1]. One of the main
reasons for the power crisis in 2008-09 was
the failure of the monsoon, which reduced
the reservoir levels in the major hydel
reservoirs (viz., Linganamakki, Supa and
Mani) by 26% compared to 2007-08 and this
led to a reduction of 29.51% (2261 MU) in
hydro generation [2]. All of these are leading
to an increased dependence on thermal
plants, whose GHG emissions are high and
pollute the environment more compared to
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Table 1 : Mega Watt scale Solar PV Plants in Karnataka State (all are under KPCL)
Place
Contractor
Yalesandra
Kolar
Rs. 20 crore
Itnal, Chikkodi
Belgaum
Rs. 20 crore
Yapaldinni
Raichur
BHEL
(yet to be commissioned)
Shivanasamudra
Mandya
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Figure 2 : Karnataka map showing the locations of all the three 3MW Solar PV Power Plants
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2. Site details
The Yalesandra plant installation site has a
steep slope with a level difference of about
15 m and there are rock outcrops in the site.
The structures for the Power Plant
comprises Solar Arrays, PCUs, control
882 m
Maximum: 40oC
12 53 & 78 09
3 MW
Date of Commission
Owner
Installed by (Contractor)
Modules
Yes
PCU (Inverters)
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PV Arrays
PCUs
z
MCBs
LT PANEL 1
TRANSFORMER 1
11 kV HT PANEL
=
TO SCADA
HT
METERING
LT PANEL 2
CUBICLE
TRANSFORMER 2
TO SCADA
LT PANEL 3
SPARE
TRANSFORMER 3
TO SCADA
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11 kV
KPTCL lines
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Tables 4 and 5 give the general technical details and the module specifications of the Plant.
13,368
[10,152 - 225 Wp ; 3216 240 Wp ]
Mono-Crystalline Silicon
1 Array
24 Modules
Arrays per MW
1st MW 181
2nd & 3rd MW 188 per MW
5.4 acre
Inclination of Modules
15 degree
S6- 60 series
225
240
28.63 V
29.62 V
7.93 A
8.12 A
37.50 V
37.62 V
8.52 A
8.55 A
1657 x 987 x 42
Cell Size
45
Weight (Kg)
19
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Transformers
Mounting structure
Type
6 x 4 Module Array
(24 modules per Structure)
Material
Mild Steel
6780 x 6030
Coating
Galvanized
Wind rating
Tilt angle
150
Foundation
PCC
Fixing type
Nut Bolts
Timelines
Foundation was laid on 9th January 2009
and the site handed over to TITAN on 28th
May 2009. 1MWp was completed on
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43,50,00,000
PCUs
5,40,00,000
Mounting structures
3,00,00,000
50,00,000
9,00,000
12,00,000
3,00,000
5,00,000
SCADA system
20,00,000
1,05,78,000
1,80,99,400
55,75,77,400
2,98,00,000
31,00,000
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3. Performance analysis
The total Energy produced by 3 MWp Plant
during the year 2010 was 3,347,480 units.
Out of this, 3,303,200 units were sold to the
grid. Figure 4 shows the contribution of all
the three Segments in the total power
Segment-3
Segment-2
Segment-1
400000
350000
300000
250000
200000
150000
100000
50000
0
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Month
Figure 4 : Contribution of all the three segments in the total power generation during 2010
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10
Segment-1
Segment-2
6000
5000
4000
3000
2000
1000
0
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Time [Daily]
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2,429,219.6 kWh
2500000
2000000
1500000
1000000
500000
Jan
Feb Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Time [Daily]
Figure 6 : Cumulative Energy Produced by Segment 1 & 2 for the year 2010
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12000
10000
8000
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Aug
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Time [Daily]
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EnergyGen (wh/day)
EnergyGen (wh/day)
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13
Inverter 1
Inverter 2
Inverter 3
Inverter 4
Inverter 5
Inverter 6
1.6M
1.4M
1.2M
1.0M
800.0k
600.0k
400.0k
200.0k
0.0
Inverter 6
1.6M
1.4M
1.2M
1.0M
800.0k
600.0k
400.0k
200.0k
0.0
Jan
EnergyGen (wh/day)
Inverter 7
Mar
Inverter 8
May
Jul
Sep
Nov
Date
1.6M
1.4M
1.2M
1.0M
800.0k
600.0k
400.0k
200.0k
0.0
Jan
Mar
May
Jul
Sep
Nov
Jan
Mar
Date
May
Jul
Sep
Nov
Date
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100
Downtime (Hours)
80
60
40
20
0
Jan
Feb
Mar
Apr
May Jun
Jul
Aug Sep
Oct
Nov Dec
Month
Figure 9: Monthly Plant down-time in hours-2010
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15
Solar Insolation
The Plant is equipped with a Pyranometer
installed at an angle of 15o, equal to the
inclination of the Modules. The Solar
Insolation recorded at the site is shown in
Figure 10. The Insolation data is not
available for about 44 days, especially from
8000
7000
5000
6000
4000
3000
2000
1000
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Time [Daily]
Figure 10: Daily Solar Insolation at the site - 2010 [@15o. inclination]
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16
Efficiency
The 2-MW plant efficiency is the combined
efficiencies of segments 1 and 2 after the
dc-ac conversion by inverters to 415 Volts
and just before stepping up to 11 kV ac. So,
this should not to be confused with the
overall plant efficiency.
Figure 11 shows the efficiency of the 2 MW
plant, that is combined efficiency of
segments 1 & 2, over the study period. The
highest efficiency achieved was 13.41% on
24th July 2010. The total energy generated
on that day was 4975.8 kWh with solar
16
14
12
10
8
6
4
2
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Time [Daily]
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60
50
40
30
20
10
Jan
Feb Mar
Jul
Nov Dec
DATE
Figure 12: Daily average temperature of PV modules (During day time) 2010
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Figure 13: Daily variation of average modules temperature, insolation (in Wh) and efficiency of the 2MW Plant
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1600
1400
Inverter-1
1200
1000
800
600
400
200
0
0
1000
2000
3000
4000
5000
6000
7000
8000
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20
1200
17000
Efficiency
Temperature
Insolation
Energy Generated
1150
1100
56
16000
900
14000
800
49
12.0
850
Efficiency (%)
15000
950
12.8
13000
750
700
42
11.2
650
09:00
12000
10:00
11:00
12:00
13:00
14:00
15:00
09:00
10:00
11:00
Time, Jan 21
Temperature ( C)
1000
1050
Insolation (W)
12:00
13:00
14:00
15:00
16:00
Time, 21-Jan
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I
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c
D
C
C
C
1
1
R
E
1
21
15.0
14.5
14.0
1000
900.0
Efficiency(%)
13.5
800.0
700.0
13.0
600.0
500.0
400.0
12.5
300.0
200.0
12.0
100.0
20.00
11.5
11.0
25
30
35
40
45
50
55
60
Temperature ( C)
Figure 16: Efficiency v/s Temperature of modules of Inverter-1 (5 min average values)
on January 21, 2010 (Color scale : Average Solar Irradiance)
14.0
13.5
13.0
12.5
12.0
11.5
11.0
25
30
35
40
45
50
55
Temperature ( C)
Figure 17: Plot of daily maximum efficiency versus temperature of modules in Inverter-1 for 2010
3
M
W
s
c
a
l
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g
r
i
d
c
o
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c
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c
D
C
C
C
1
1
R
E
1
22
14000
12000
10000
8000
6000
4000
2000
09:36
10:48
12:00
13:12
14:24
15:36
16:48
18000
16000
14000
12000
10000
8000
6000
4000
2000
09:36
10:48
12:00
13:12
14:24
15:36
70
15
14
60
13
12
50
11
10
40
9
8
30
7
20
09:36
10:48
14
60
13
12
50
11
10
40
9
8
30
7
20
10:48
10000
8000
6000
4000
2000
14:24
15:36
12000
14
13
12
50
11
10
40
9
8
30
7
20
10:48
10000
8000
6000
4000
2000
14:24
15:36
12000
6
16:48
15
14
13
12
50
11
10
40
9
8
30
7
20
09:36
10:48
12:00
13:12
14:24
15:36
6
16:48
12000
10000
8000
6000
4000
2000
14:24
15:36
16:48
14000
70
14
60
12
50
10
40
8
30
20
09:36
10:48
12:00
13:12
Time (Sept-20)
Figure 18: (Left) Daily plots showing variation of energy generation with insolation;
(Right) Daily plots showing variation of efficiency with modules temperature
3
M
W
s
c
a
l
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g
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a
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14:24
15:36
16:48
Efficiency (%)
16000
15:36
60
16:48
18000
Time (Sept-20)
14:24
Time (July-24)
1200
1100
1000
900
800
700
600
500
400
300
200
100
13:12
13:12
70
Time (July-24)
12:00
12:00
Efficiency (%)
14000
10:48
6
16:48
15
09:36
16000
09:36
15:36
60
16:48
18000
13:12
14:24
Time (June-18)
1200
1100
1000
900
800
700
600
500
400
300
200
100
12:00
13:12
70
Time (June-18)
10:48
12:00
Efficiency (%)
14000
09:36
6
16:48
15
09:36
16000
13:12
15:36
70
16:48
18000
12:00
14:24
Time (May-11)
1200
1100
1000
900
800
700
600
500
400
300
200
100
10:48
13:12
Time (March-24)
Time (May-11)
09:36
12:00
Efficiency (%)
1200
1100
1000
900
800
700
600
500
400
300
200
100
Time (March-24)
16000
18000
Efficiency (%)
1200
1100
1000
900
800
700
600
500
400
300
200
100
Energy Generation
Efficiency
Solar Insolation
Temp Mod
R
e
p
o
r
t
I
I
S
c
D
C
C
C
1
1
R
E
1
23
?
Presently the modules are cleaned by
s p r a y i n g w a t e r. B u t t h e d u s t
accumulated on the modules turns into
paste form once the modules are water
sprayed, making it difficult to remove.
Also, the height of the modules
mounting structures (see Figure 19)
makes it impossible to remove the dirt
completely with wipers while standing
on the ground. This has led inevitably, to
the option of cleaning the modules by
climbing on top of them (and then using
wipers!). This will weaken the strength
of solar modules as well as mounting
structures in the long run and also affect
the power production. Hence, it is felt
that there is a need to address this issue
by developing alternate method/
technology for cleaning the PV
modules.
?
Recently, some of the modules have
shown change in color (see Figure 20).
It is yet to be ascertained whether this
color change in the modules has any
negative impact on their performance.
Figure 19: Photo of PV Plant showing the modules mounting structures inclined at 150.
3
M
W
s
c
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1
1
R
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1
3
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24
R
e
p
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t
I
I
S
c
D
C
C
C
1
1
R
E
1
25
5. Conclusion
The performance of the 3 MWp Yalesandra
solar photovoltaic power plant has been
analyzed for the year 2010. The total
electrical energy generated by the
Yalesandra power plant during 2010 was
3.34 million kWh and 3.30 million units were
sold to the grid. Based on the performance of
the first two segments we estimate the mean
output to be 6655 kWh per day. This is lower
than expected for a solar power plant and is
on account of teething trouble associated
with inverters and the grid-encountered in
the first year of the operation of the plant. It
was found that failure in inverters were the
most frequent incidents. This is mostly
caused by lack of experience in the initial
production stage and some unexplained
inverter failures might be caused by
disturbance from the grid and other
interconnected issues [6].
The impact of temperature variation (of
modules) on the performance of
photovoltaic mono-crystalline silicon
modules was studied both on daily and
yearly basis (daily average values). It is
observed that the efficiency of modules is
more sensitive to temperature than the solar
insolation. The normal daily trend is that the
efficiency of Plant is high during morning
hours but low during the middle of the day
and again starts increasing from late
3
M
W
s
c
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C
C
1
1
R
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1
26
6. References
1
.A
n
t
o
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3
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,
C
E
(
E
I
&
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)
/
S
P
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,
K
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a
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5
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3
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,
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6
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o
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a
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p
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y
s
t
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m
s
:
T
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c
h
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a
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p
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a
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1
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.
3
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I
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1
1
R
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1
27
7. Acknowledgements
W
e
w
i
s
h
t
o
t
h
a
n
k
M
r
.
B
.
R
.
N
a
g
a
r
a
j
u
,
E
x
C
h
i
e
f
E
n
g
i
n
e
e
r
,
R
E
P
r
o
j
e
c
t
s
,
K
a
r
n
a
t
a
k
a
P
o
w
e
r
C
o
r
p
o
r
a
t
i
o
n
L
t
d
.
(
K
P
C
L
)
f
o
r
p
a
r
t
i
c
i
p
a
t
i
n
g
i
n
t
h
e
p
r
o
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c
t
b
y
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i
v
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g
a
u
t
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o
r
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z
a
t
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o
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t
o
c
o
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l
e
c
t
a
n
d
u
s
e
d
a
t
a
f
o
r
t
h
i
s
r
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s
e
a
r
c
h
.
W
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t
h
a
n
k
M
r
.
A
.
V
.
V
.
R
e
d
d
y
,
E
x
e
c
u
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E
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g
i
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r
,
i
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c
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a
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K
o
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a
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a
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a
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p
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a
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t
.
W
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s
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p
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W
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.
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a
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D
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,
K
P
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a
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,
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.
3
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c
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c
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p
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K
o
l
a
r
,
K
a
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n
a
t
a
k
a
Satellite image of the 3-MW scale grid-connected solar photovoltaic power plant at Kolar, Karnataka
REPORT IISc-DCCC 11 RE 1
AUGUST 2011