Typical Layout

Typical single tracker block is 200kW. Depending on the land contour, orientation and shape, the block sizes can vary from 100kW to 500kW

A complete plant layout is created by using multiply tracking blocks. For example, a 1MW plant will have 5 tracker blocks of 200kW each

Each tracking block contains rows of torque tubes, and each torque tube is mounted with several PV modules.

In the design shown above, every tow has 40 nos 300w module. 17 rows in a single tracker block. Thus, the power generated by this tracking block is 300*40*17=204kW.

Each tracking block requires a single controller and a single unit of drive/motor/actuator. To generate 1MW, upto 5 such blocks will be needed, each of 204kW

If a land contours allow for a single tracker block of say 350kW (by increasing the number of rows) then a 1MW plant will require 3 tracker blocks

Tracker Controllers and Software

IMPORTANT FEATURE

Standalone Tracker controller option is also available

  1. PCU and battery from independent locally installed single 250w module (for a 250 kW tracker block)
  2. WiFi enabled inter tracker controller and Wind station communication system

Installation of this hardware makes a tracker controller work without any external power and data connections. A true STAND ALONE mode of operation.

If 4 nos of tracker controllers (250kW each) are required for 1MW, over an area of 5 acres, then there is NO Data or Power Cabling required.

Substantial cost saving can be achieved for the cabling and civil costs.

Highlights of the control system and software are:

  1. Back Tracking with Azimuth correction – avoids the shading of the rows of PV modules on the shaded side – depending on time of day. This is a very advanced and proprietary algorithm and takes into account the spacing and module size. This ALSO takes into account the Azimuth of the sun and adjusts the tracker tilt based on the solar azimuth.
  2. Field Slope: Trackers are sometimes sited on land that is sloped in the E-W direction. The tracker is able to take this slope as a parameter and perform backtracking flawlessly in this condition.
  3. Tracker stowing at wind speeds – The tracker reduces its presented cross section to the wind in case of increase in the wind speed beyond a preset limit, thereby reducing the force on the tracker mechanical structure. The anemometer continuously sends the wind speed to the tracker where an algorithm calculates when the stowing is required.
  4. Electronics – has been tested for an operating range of 0o C to 50o C. All the boards have a conformal coating on it and are designed to resist damage due to condensation.
  5. Lowest power consumption – The tracker is designed to move a rotationally well-balanced system and because of frictionless movement, the power consumption of the entire system is very low - typically less than 0.02% of the energy generated by a plant situated in a good location.
  6. Control Algorithms – The tracker functions on well-tuned PID algorithms. This makes the system smoothly position itself between two positions without excessively stressing the mechanical structure or causing any overshoot. This also reduces the overall power consumption of the tracker plant.

Pivoting Options

The pivoting mechanism/option selected in a tracker is very important as that may require maintenance, lubrication, cleaning and replacement.

The two option available from Scorpius Trackers DO NOT require any maintenance.

Structure Design

Our structures have been designed to be robust, resilient, reliable, low maintenance, and low cost.

Main Features:

  1. Rotationally Balanced Structures
  2. Robustly designed and built to withstand high wind conditions
  3. Bearings and pivots are lubrication and maintenance free for the life of the system
  4. All steel hot dip galvanized to minimum 80 microns (as per requirement)
  5. Low number of drive motors per MW, reducing potential points of failure
  6. Panel mounting flexibility supports one PV panel in portrait, two panels in landscape, or three panels in landscape to facilitate optimal configuration for your site
  7. Available as only design only, structure material supply or fully installed to eliminate installation cost uncertainty
  8. Hardware is provided with speciality surface treatment like Zn-Co plating / Zn-Ni coating / Hydrogen De-embrittlement etc. for a long life

Project Design

Plant Layout

A layout is decided by considering the land contour, slopes, orientation and factors like location of inverters, roads, shading etc.


Structure Design

FEA of structures for site conditions specified is carried out.


Civil Design

Civil foundation design is done as per soil test reports and wind conditions.

Technology Selection

The team of experts from Scorpius have a vast experience in astro physics, mathematics, mechanical and civil engineering, materials, polymers etc. and can provide consultancy to answer the following querie.

Plant Sizing

  • Size optimization for Shading
  • Use Back tracking
  • Tracking for minimal increase (20%) in efficiency but lesser capex?
  • OR tracking for maximum increase in efficiency (35%) with max Capex?

Solar Technology

  • Thin Film?
  • Mono Crystalline
  • Poly Crystalline
  • CPV

Tracking Technology selection

  • Single axis Horizontal Tracked
  • Single Axis Equatorial Tracked
  • Dual Axis pole mounted
  • Dual Axis tilt and roll

Optimal configuration is selected based on size and shape of available land, location and purpose of installation and PV technology selected

Monitoring and Predictive Maintenance

All tracker controllers installed in a plant will send data to the Cloud (and to a central server at Scorpius)

This data consists of all critical parameters of the tracker controller, motors, wind station and batteries.

System and battery currents, voltages, charge/discharge plots, wind speed, structure shake, controller temperatures also can be monitored.

A GUI console is available to customers to monitor the performance and also to do predictive maintenance of the site.

For example, if a tracker motor usually draws 2A current but it suddenly starts drawing higher current, then it could mean that there is some mechanical resistance developing in the system and needs to be checked.