Solar Plant HT Evacuation
Do’s & Don’ts That Decide Efficiency & Safety
In solar projects, most attention goes to modules and inverters.
But real long-term reliability is decided at one critical stage:
HT Evacuation System Design & Execution.
Poor HT planning =
⚠️ Technical losses
⚠️ Transformer failures
⚠️ Relay mal-operations
⚠️ DISCOM penalties
⚠️ Safety risks
Let’s break it down clearly.
✅ DO’s – Solar Plant HT Evacuation
🔹 1️⃣ Design & Engineering Excellence
✔️ Finalize HT voltage level (11 / 22 / 33 kV) strictly as per DISCOM approval.
✔️ Place inverter-duty transformers close to inverter blocks to reduce I²R losses.
✔️ Optimize HT feeder routing to avoid unnecessary cable length.
✔️ Size HT conductors based on:
-
Full load current
-
Permissible voltage drop
-
Thermal limits
-
Short circuit withstand capacity
✔️ Keep provision for future capacity expansion in layout planning.
🔹 2️⃣ Equipment & Installation Discipline
✔️ Use only DISCOM-approved HT equipment:
-
VCB / RMU
-
CT / PT
-
Lightning Arresters
✔️ Ensure calibrated torque tightening for all HT terminations.
✔️ Engage certified jointers for HT cable termination.
✔️ Maintain minimum bending radius as per cable manufacturer guidelines.
✔️ Provide oil soak pits & fire barriers for power transformers.
HT installation quality directly impacts plant availability.
🔹 3️⃣ Protection & Safety Integrity
✔️ Properly coordinate protection schemes:
-
Overcurrent (OC)
-
Earth Fault (EF)
-
Under/Over Voltage (UV/OV)
✔️ Perform mandatory pre-commissioning tests:
-
IR Test
-
HV Test
-
Contact Resistance
-
Secondary Injection
-
Relay Testing
✔️ Ensure earthing resistance is within acceptable limits.
✔️ Install Lightning Arresters at all incoming/outgoing line points.
✔️ Follow strict LOTO and work permit systems.
HT safety is non-negotiable.
🔹 4️⃣ Documentation & O&M Controls
✔️ Record and archive all relay settings and test reports.
✔️ Clearly label feeders, panels, transformers, and cable routes.
✔️ Conduct periodic monitoring of:
-
Voltage profile
-
Feeder losses
-
Transformer temperature
-
Hotspots via thermography
Engineering discipline continues after commissioning.
❌ DON’Ts – Solar Plant HT Evacuation
🚫 Design Mistakes
❌ Don’t create unnecessarily long HT routes.
❌ Don’t ignore voltage drop and technical loss calculations.
❌ Don’t proceed without DISCOM coordination.
❌ Don’t mix radial and ring main logic without clear protection philosophy.
🚫 Installation Errors
❌ Don’t allow loose, under-torqued, or over-torqued joints.
❌ Don’t use unapproved connectors, lugs, or cable accessories.
❌ Don’t leave exposed strands at terminations.
❌ Don’t allow wrong phase identification or phase sequence mismatch.
One loose joint can cause major outages.
🚫 Safety Violations
❌ Never perform live HT work.
❌ Never energize without confirming earthing continuity.
❌ Never allow untrained manpower inside HT zones.
❌ Never bypass protection during trial charging.
Shortcut today = shutdown tomorrow.
🚫 O&M Negligence
❌ Don’t skip periodic thermography inspections.
❌ Don’t operate with defective relays or faulty Lightning Arresters.
❌ Don’t ignore abnormal sound, overheating, or voltage imbalance.
Early detection prevents major failure.
🔑 Key Engineering Insight
HT evacuation is not just about transferring power to the grid.
It determines:
✔️ Plant efficiency
✔️ Grid compliance
✔️ Safety of manpower
✔️ Long-term reliability
✔️ Financial performance
Most technical losses and failures happen because of what we ignore — not what we design.
If you're a Solar EPC, Electrical Consultant, or QA Engineer working on 11kV / 33kV evacuation systems, disciplined HT execution can protect your entire project margin.
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