This is the presentation of my Summer Internship at "WAAREE Energies Ltd." which is a Solar manufacturing company infect India's No.1 solar manufacturing company. I thought it will be great if i will share this knowledge of mine with everyone. Hope everyone will like this.

1. Summer Internship Presentation
AT
WAAREE Energies Pvt. Ltd.

2. Acknowledgement
• Firstly I would like to thank Mr Narendra Balkishan Soni (Head of
Department, Department of Electrical and Power Engineering,
UPES) for meticulously planning academic curriculum in such a way
that students are not only academically sound but also industry ready
by including such industrial training patterns.
• I would specially like to thanks Dr. Santosh Dubey (Associate
Professor, Department of Physics, UPES) for the positive attitude he
showed for my work and recommended me to the WAAREE.
• Finally, I would also like to thanks Mr. Jignesh Rathod (Deputy
General Manager), Mr. Vishal Upadhyay (HR and Admins. WAAREE
Energies Ltd.) , Mr. Varun Singh Panchal (Manager- Operations,
WAAREE Energies Ltd.) for giving me this opportunity and their
guidance during the course of the internship.

3. Company Background
• The WAAREE Group consortium was founded in 1989 with a focus on
Instrumentation; they have since established themselves as India’s
premier multi-diverse technology group.
• In 2007 WAAREE began its foray in renewable energy with the
establishment of WAAREE Energies Pvt Ltd (WEPL). WEPL has a
modern state-of-the-art & automatic production line for PV modules at
the Surat Special Economic Zone (SEZ), located 250 km. north of
Mumbai.
• A full range of PV modules from 1Wp to 300Wp are manufactured for
various on-grid and off-grid applications, and are exported to a number
of countries globally, and in India.
• They provide complete EPC services to developers and promoters of
Solar Power Generations Systems, Solar Power Plants & Solar Off Grid
Power Plants

4. Factsheet
NATURE OF BUISNESS MANUFACTURER
ADDITIONAL BUISNESS  EXPORTER
 SERVICE PROVIDER
 ASSOCIATION
 DISTRIBUTOR
TOTAL NUMBER OF
ENPLOYEES
501 – 1000 PEOPLE
YEAR OF ESTABLISHMENT 2007
LEGAL STATUS OF FIRM PRIVATE LIMITED COMPANY
ANNUAL TURNOVER RS. 100- RS. 500 CRORE

5. • Our Vision is to provide high quality and cost effective sustainable
energy solutions across all the markets, reducing carbon footprint-
paving way for sustainable energy thereby improving quality of present
and future human life.
• By virtue of our commitment to our stakeholders, we strive for
continuous improvement in the quality of our product and services.
• The core values of our organization are those values that underline our
work & strategies we employ to fulfil our Vision & Mission.
Vision, Mission, and Values

6. Quality Department
• A quality engineer is a professional who understands the
principals of product and service quality evaluation and control,
according to the Energy Facility Contractors group. Quality
engineers work in manufacturing plants, taking responsibility for
the quality of a company’s products.
• Quality standards provide guidance and tools for companies that
want to ensure their products and services consistently meet
customer’s requirements, according to the International
Organization for Standardization.
SOLAR CELL
EVA SHEET

7. BUS BAR/ RIBBON
TAMPERED GLASS
ALUMINIUM FRAME
JUNCTION BOX
BACKSHEET

8. Quality Lab Tests
CELL TESTER
• All the
electrical
parameters of
a cell is tested.
• Visual tests
are also
performed
GEL
CONTENT
TEST
• To check
the
bonding of
EVA (EVA
to back
sheet and
EVA to
glass)
• To check
the
durability
of EVA
PRESSURE
COOKER
TEST
• Checks the
efficiency
of Back
Sheet
IP 67 TEST
• To check the quality
sealant
PEEL TESTER
• To check the
bonding of EVA with
Back Sheet and
Glass

9. Shop Floor
• Information about Standard Solar Cell;-
 Standard size of solar cell worldwide is 156.75X156.75 mm
 A standard solar cell consists of 105 fingers which is updated from 95
fingers.
 4 BB (Bus Bar) solar cells are in use but very soon 5BB solar cells are
expected to arrive in the market.
 Temperature = 24+-2 degree Celsius
 Voc = 0.6 volt
 Isc = 8 amp
 P = 4.8 Watt
 Irradiance = 1000 w/m2
 Width of front Bus Bar is 1.3 mm
 Width of Bach Bus Bur is 2.21 mm
 Thickness of cell is 0.200+-20 microns

10. • Important Points regarding the Designing of modules;-
 P (Wattage of a Module) = (Efficiency of Cell (in %) * No. of Cells
*Cell Area *irradiance)
 Cell Area in m2
 Irradiance in 1000 W/m2
 Module Efficiency = (P max)/ (Module Area)
 Fill Factor = (P max)/(Voc*Isc)
 Bus Bar width = 5 mm
 Bus Bar thickness = 0.300+-20 microns
 Solar Cells are imported from companies like Indo Solar, Jupiter, etc.

11. Tabbing &
Stringing
Layup
Section
Inline EL
Laminator
Trimming
Section
Visual
Examination
JB Placing
Section
Frame
Placing
Section
Offline EL

12. Visual Acceptance Criterion
S.No. Defect Acceptance Criteria Measurement
Method
1. Cell crack No Visible cell crack is accepted Visual Inspection
2. Cell chipping/ Edge chipping 1. V chip not allowed.
2. Silicon chip up to 0.5X0.5
mm allowed
3. U chip: L<=2 mm &
H<=0.5 mm
Steel Gauge
3. Cell to cell gap 2+-0.5 mm (1.5 to 2.5 mm) Visual Inspection
4. Yellowish spot on ribbon No yellow spot on ribbon
accepted
Visual Inspection
5. Ribbon cross <= 0.5mm ribbon cross on max 3
cells per module
Steel Gauge
6. Grid line cut <=1mm , Qty. <=6 per module Scale
7. Colour variation in cells Reddish or dark blue and rest of
the part light blue not
acceptable
Visual Inspection
8. Colour variation in string Reddish or dark blue mixing
with light blue
Visual Inspection

13. Merlin Department
• MERLIN SOLAR
Conventional forms of solar deployment which rely on aluminium-framed-
tempered-glass constructs are the industry work horse. However, their weight
and rigidity prevent their use in applications that demand rugged, lightweight,
flex tolerant, and aesthetic appeal. This has limited their use primarily to
large grid connected solar farm applications. Merlin™ delivers innovative
crystalline silicon based solar solutions which address demanding
deployments such as on metal roofs, auxiliary power for transportation, flush
mounted residential solar, and military applications.
• Why Merlin?
 The Merlin module offers improved light capture and reduced sheet
resistance
 Overall power output is 14% higher than the conventional modules
 Merlin performs significantly better than conventional modules in low-
angle incidence conditions (6:30 AM – 9:00 AM and 2:00 PM – 6:00 PM),
as well as low light conditions

15. MERLIN CELLS VS CONVENTIONAL CELLS
• 10% reduction in total installed system cost compared to conventional
systems
• Up to 80% less silver than traditional three bus bar cells and modules
• Up to 50% lighter in weight, making it easier to install, transport and
allows placement of panels in areas where traditional panels could not
be installed
• 3-5% power increase per module compared to standard modules
• Increased durability and flexibility improves dynamic loading
performance and reduces breakage during transportation and
installation
• Flexible grid eliminates three bus bar cell metallization, increasing fill
factor and reducing shading losses, resulting in higher current and
increased efficiency
• Wide, flexible grid connecting tabs allow for durable cell-to-cell
connections, improving reliability at the same time as their high
conductivity increases module efficiency

16. Submitted By:-
SASHIKANT TIWARI
sashikant0611@gmail.com