Product Report Pregalvanised PU Coated Mounting System from Seven Energies Ltd Seven Energies Limited is the first

t Company in India to introduce Pregalvanized Module Mounting Structures for Solar industry. This has been proven over time by implementation in large scale projects across the country. The basic requirement of a mounting system for Solar PV modules is to support the solar modules at the designed angle within permissible deflections, provide proper load transfer to the ground foundation, resist the module from getting uprooted under expected winds and corrosion free performance during the project life. It is these requirements, which have driven the authors to look for an alternative to the conventional rolled sections of hot dip galvanised structures. The pregalvanised Mounting System being offered by Seven Energies Limited is born out of this zeal to provide the best solution to the SPV industry. Different standard profile sections are available in the market which can be designed to an optimum configuration of the structure, and the member selection will be done from these sections to give the most economical design duly satisfying the structural strengths suiting the soil profile and expected wind loading. The profiles are of cold rolled steel manufactured in a controlled factory environment. The profiles are rolled using 120 GSM pregalvanised steel sheets of reputed make, and are painted with Polyurethane coating system to enhance the corrosion resistance and longevity. The coating system is SOLVO THANE MC SOLAR 7227, a Moisture Cured Polyurethane coating and a proprietary item manufactured by Solvosol Paints Pvt Ltd. The primer coat is Single pack Moisture Cured Polyurethane Primer 30-40 Micron and finish coat is Single pack Aliphatic Moisture Cured Polyurethane. The advantages of such painting scheme vis-a-vis hot dip galvanisation are enumerated below: Hot Dip Galvanization: In case of hot dip galvanizing, it is not automatic. The important parameters such as pre heating, aluminum content in the zinc bath, contact time and most importantly, passivation subsequent to galvanization are totally uncontrolled. The alloy layer which forms with instantaneous metallurgical reaction between zinc and iron at 4400C is totally uncontrolled. Though the galvanizing thickness per se is high, the uniformity and quantity of pure zinc layer varies drastically over different points of surface of the steel, and this affects the salt spray corrosion resistance performance. Though a passivation is prescribed after galvanizing, the same is hardly done in practice, as it is a complicated mechanism. In the olden days, chromate conversion coatings with specific ratio of trivalent chrome and hexavalent chrome were maintained. Off late lot of compounds have come, which are chromate free. However, the crux of the matter is properly passivated galvanized steel should pass 100hrs of salt spray test before appearance of white rust. However, usually the white rust starts appearing in about 10-20 hrs itself. Our polymeric coating on Pregalvanised sheet: We are offering moisture cured polyurethane coating system, which is the latest in urethane coating technology and it is superior to conventional two pack polyurethane coatings. The system is applied over pre-galvanized surface to enhance the life of galvanized steel tremendously. The system comprised of 2 coats. The first coat is MC Clear primer, to fill up all the micro pores and it has excellent encapsulation properties. It also offers excellent adhesion properties on galvanized surface, without use

of etch primer. The finishing coat is of moisture cured aluminum, and this offers excellent weather resistance and corrosion resistance properties. Because of the lamellar structure of aluminum, corrosion rates are much lower. So, these coatings together, act as a first barrier to galvanized surface and increase the life of galvanized steel. Even Epoxy coating is not comparable to a metallurgical coating like Polyurethane. Epoxy coating with an epoxy equivalent of 400 only will give long life. Nearest comparison to PU Coating is 100% solids epoxy coating to a thickness of 1.5 to 2.00 mm. However, being a two pack system mixing errors are inherent drawback of the system unlike the PU system which is a single pack system. Polyurethane coating is also UV resistant, while UV resistance of Hot Dip Galvanization depends greatly on quality of Galvanization and hence cannot be ensured. Epoxy coatings have no UV resistance whatsoever and they require further protection with aliphatic polyurethane of a min coating of 40 micron. Salt Spray Testing Results: We have conducting salt spray tests at Indian Institute of Chemical Technology, Hyderabad on 120 GSM pre galvanised Polyurethane coated sheet and it has already passed 4000hrs without any corrosion, and the tests are continuing till failure. While a pre galvanised sheet of 250gsm, without paint coating has failed in the test, as red rust appeared at 1000 hours of salt spray. Result would not vary much in case of hot dip galvanised sheet too. From the above, it can be safely concluded that the expected life of pregalvanized steel coated with our coating system, will surely meet the project requirement of Solar PV Projects of ~ 20-25 years for corrosion free life, with a nominal periodic maintenance done properly.

The structural features of the mounting systems offered by Seven Energies Limited with cold formed hollow steel profiles are: o Hollow closed sections which provide good rigidity and stability o Reduced Deflections o Resistance to wind > 180 kmph; Seismic Zone V (design as per IS/ ASTM standards suiting the wind profile of the location) o Fire proof with a rating of one hour o Easy to handle and erect and hence speed in execution o Needs only 75% steel than normal rolled section. Though the profile cost is higher and after adding for the painting cost, it is competitive compared to Hot Dip Galvanised Structure on a Per MW basis.

Demo Structure erected at Gujarat Solar Park, Charanka Load Test witnessed and Validated by LD Engineering College, Ahmedabad

Design Approved by JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY , HYDERABAD after a LOAD TEST on this Demo Structure in Hyderabad

Erected Structures by Seven Energies with their Product at 9 MW ICML Project in Gujarat for ETA, New Delhi

Structures after fixing the modules at the same project Authors:

Structures after fixing the modules at the same project

K.Vijaya Bhasker Director, Seven Energies Limited, Hyderabad A Post Graduate Structural Engineer from NIT, Warangal, worked for over 27 years with organizations of repute like AP Genco and L&T Limited and involved in Design and implementation of various High Value Power and Infrastructure Projects in India. K Venkateswarlu Corrosion Prevention Expert A Post Graduate from IIT, Kharagpur. Graduated in Chemical Engineering from Andhra University and Post Graduated from IIT, Kharagpur in Petroleum Refinery Engineering and Petrochemicals. Worked with Paints Division of ICI for 12 years, worked with Nagarjuna Steels and Nagarjuna Coated Tubes (flow-coat tubes) for 10 years, last held position was General Manager Exports and was associated with Tata Exports too, as consultant. Trained in USA and Malaysia on Polyurethane and Acrylic Coatings. Travelled abroad extensively and all along associated with Corrosion Protection through surface coatings. A major part of 35 years industrial experience is devoted to special coatings like Polyurethanes, Epoxies and Acrylics.