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Sohaib Khan, Democratic Republic of the (2026)

19/04/2026

👉 Pyranometer

What is a Pyranometer?

A pyranometer is an instrument used to measure solar radiation (sunlight energy) falling on a surface. It is widely used in:

Solar power plants ☀️

Weather stations 🌦️

Climate research

What does it measure?

It measures Global Horizontal Irradiance (GHI), which includes:

Direct sunlight

Diffused sky radiation

Where is it used (your field relevance)?

Since you are in solar planning/engineering, pyranometer is used for:

Solar plant performance monitoring

Site assessment (how much sunlight area gets)

SCADA systems in solar projects

Simple Example:

If a pyranometer shows 800 W/m², it means: ➡️ 800 watts of solar energy is falling on 1 square meter area.

13/04/2026

QC Engineer: Responsibilities
 Ensuring that all heating, ventilation, and air conditioning installations meet technical specifications, and performance standards.
 Implementation of the approved DWGs, ITPs, and checklists for HVAC works on site.
 Inspection of incoming materials and equipment against approved submittals and manufacturer certifications to prevent the use of noncompliant or substandard material.
 Conduct daily inspections for HVAC activities.
 Interface with project managers, consultants, and clients during quality audits and weekly coordination meetings to resolve technical issues.
 Reviewing mechanical drawings
 Ensuring that sensitive equipment is stored in climate controlled or weather protected areas to prevent rust or electrical failure before installation.
 Witness and record tests and inspections (DFT, adhesion, pull-off tests, visual checks, mock-ups).
 Issue Inspection Requests (IRs) and coordinate inspections with consultant/client.
 Identifying nonconformities and monitor corrective actions.
 Maintain quality records, including inspection reports, test results, and approvals
Coordinate with construction team to ensure QC clearance before proceeding to subsequent activities.
 Observing technicians to ensure they are using the correct tools and methods

06/04/2026

AC and DC earthing systems are different in purpose and design, even though both are for safety and proper operation.

⚡ 1. AC Earthing System

🔹 What it is

Earthing used in AC (Alternating Current) systems like:

Transformers

Generators

Buildings

Industrial power systems

🔹 Types of AC Earthing

1. Equipment Earthing (Body Earthing)

Connects metal body to earth

Prevents electric shock

2. System Earthing (Neutral Earthing)

Neutral of transformer/generator is grounded

🔹 Common Methods

Solid earthing

Resistance earthing

Reactance earthing

Unearthed system

🔹 Key Features

Handles alternating fault currents

Important for fault clearing & protection

Used in substations and distribution systems

⚡ 2. DC Earthing System

🔹 What it is

Used in DC (Direct Current) systems, such as:

Battery banks

Solar power plants

UPS systems

Telecom systems

🔹 Types of DC Earthing

1. Positive Earthing

2. Negative Earthing

3. Floating (Unearthed) System

🔹 Key Features

Controls leakage current & corrosion

Maintains system stability

Helps detect earth faults

⚖️ AC vs DC Earthing (Simple Comparison)

Feature AC Earthing DC Earthing

Current Type Alternating Direct
Main Purpose Safety + fault clearing Stability + fault detection
Neutral Usually earthed May be +, − or floating
Usage Transformers, grids Solar, batteries, UPS

🔥 Practical Example (Site Level)

In a transformer-based system → AC earthing used

In a solar plant:

Panel structure → AC equipment earthing

Battery/DC side → DC earthing

⚠️ Important Rule

Never mix AC and DC earthing improperly

Keep separate earth pits if required (as per design)

Follow standards like:

IEEE

IEC

04/04/2026

Central inverter (especially in solar PV plants) installation is a critical activity and must follow proper QA/QC and safety procedures. I’ll explain it in a step-by-step practical site method (useful for Electrical QA/QC & site engineers 👇):

🔧 Central Inverter Installation – Step by Step

📌 1. Document & Drawing Verification

Approved GA drawing (General Arrangement)

SLD (Single Line Diagram)

Foundation drawings

Vendor manual (e.g., Sungrow Power Supply Co., Ltd., Huawei Technologies, ABB Ltd.)

👉 Check:

Location coordinates

Cable entry points

Clearance space

📌 2. Material Inspection (MIR)

Verify inverter model, rating (e.g., 2.5 MW / 5 MW)

Check for:

Physical damage

Nameplate details

Accessories (bolts, glands, fans, filters)

Prepare MIR (Material Inspection Report)

📌 3. Foundation Preparation

Ensure civil foundation is:

Level (use spirit level)

As per approved drawing

Anchor bolts aligned

👉 Check:

Elevation & dimensions

Grouting area clean

📌 4. Inverter Placement (Shifting & Positioning)

Use crane / hydra for lifting

Follow lifting points (as per vendor manual)

⚠️ Important:

Do not tilt excessively

Avoid shock/vibration

👉 Place inverter on foundation carefully

📌 5. Alignment & Leveling

Use:

Spirit level

Theodolite (if required)

👉 Ensure:

Proper alignment

No tilt

📌 6. Bolting & Grouting

Tighten anchor bolts

Use torque wrench (as per spec)

Do grouting using non-shrink grout

📌 7. Earthing (Grounding)

Connect inverter body to earth pit

👉 Normally:

2 separate earth connections:

Body earth

Lightning earth

⚠️ Ensure:

Proper lug crimping

Earth resistance within limit (

19/03/2026

step-by-step process for Combiner Box (DC Combiner Box) installation in a solar power project. This is typically used in utility-scale or large rooftop systems.

🔧 1. Pre-Installation Preparation

Review drawings: SLD (Single Line Diagram), layout, and cable routing plan

Check materials:

Combiner box (with fuses, SPD, isolator)

Mounting structure / pole

DC cables, glands, lugs

Tools & safety:

Insulated tools, PPE (helmet, gloves, safety shoes)
📍 2. Location & Mounting

Install near module arrays (to reduce DC losses)

Ensure:

Proper height (generally 0.8–1.2 m above ground)

Easy accessibility for maintenance

Fix mounting structure firmly (structure or pole-mounted)

Tighten all bolts and check alignment

⚡ 3. Cable Entry & Glanding

Route string cables from solar modules to combiner box

Use proper cable glands (IP65/IP67 rated)

Ensure:

No sharp bends

Proper clamping

Weatherproof sealing

🔌 4. String Connection (Input Side)

Connect positive (+) and negative (–) of each string:

Positive → fuse terminal

Negative → common negative busbar

Check polarity carefully (VERY IMPORTANT)

Label each string clearly

🔋 5. Internal Connections

Check internal wiring:

Fuse links installed properly

Surge Protection Device (SPD) connected

Earthing terminals available

Torque all connections as per manufacturer specs

⚡ 6. Output Cable Connection

Connect output cables from combiner box to:

Inverter / Inverter Room

Ensure:

Proper lug crimping

Tight termination

Correct polarity

🌍 7. Earthing (Grounding)

Connect combiner box body to earthing pit

SPD earthing must be properly connected

Use recommended earthing cable size (e.g., 6–16 sq.mm GI/Cu)

✅ 8. Testing & Inspection

Continuity test

Insulation Resistance Test (IR test using megger)

Polarity check

Voltage measurement of strings

Ensure no loose connections

🚀 9. Commissioning

Close fuses / isolator

Monitor current from each string

Check for:

Abnormal heating
Fault alarms
Record initial readings

📊 10. Documentation

Update as-built drawings

Maintain test reports

Label combiner box properly (ID, danger signs)

⚠️ Important Safety Points

Never connect under load

Always verify polarity before connection

Use insulated tools

Follow LOTO (Lock Out Tag Out) procedure

Checklist Format (Site Ex*****on Use)
DC Combiner Box Installation Checklist
- [ ] Drawings reviewed (SLD, layout, routing)
- [ ] Materials verified (box, fuses, SPD, isolator, cables, glands, lugs)
- [ ] Tools & PPE available
- [ ] Mounting structure fixed and aligned
- [ ] Cable glands installed (IP65/IP67)
- [ ] String polarity checked and labeled
- [ ] Fuse links & SPD connected
- [ ] Output cables terminated with correct polarity
- [ ] Earthing connected (body + SPD)
- [ ] Continuity, IR, and polarity tests completed
- [ ] Voltage measurement recorded
- [ ] Combiner box labeled (ID, danger signs)
- [ ] As-built drawings updated

17/03/2026

Solar PV module installation process (EPC site ex*****on level):

🔧 Pre‑Installation Checks
- Survey & Layout: Verify pile foundations and mounting structures are aligned as per drawings.
- Material Inspection: Check modules for cracks, junction box integrity, and serial numbers.
- Safety Setup: Ensure scaffolding, PPE, and grounding arrangements are in place.

⚙️ Mounting Structure Preparation
- Torque Check: Tighten bolts/nuts of the MMS (Module Mounting Structure) to specified torque.
- Tilt & Orientation: Confirm tilt angle and azimuth direction match design.
- Cleaning: Wipe MMS surfaces to remove dust/oil before placing modules.

🔩 Module Placement
- Lifting & Handling: Use two persons or mechanical lifters to avoid micro‑cracks.
- Positioning: Place modules on MMS rails, ensuring uniform gaps between panels.
- Clamping: Fix modules with mid‑clamps and end‑clamps, tightened to torque specs.

⚡ Electrical Connections
- String Formation: Connect modules in series using MC4 connectors.
- Polarity Check: Verify positive/negative terminals before closing connections.
- Cable Management: Route DC cables neatly with UV‑resistant ties, avoiding sharp bends.

🛡️ Earthing & Safety
- Module Earthing: Connect module frames to earthing strip using copper wire.
- Lightning Protection: Ensure down conductors are properly bonded.

✅ Quality & Commissioning
- IV Curve Testing: Measure string output to confirm performance.
- Visual Inspection: Check for loose clamps, cable routing, and shading issues.
- Documentation: Record module serial numbers, string configuration, and test results.

16/03/2026

step-by-step process for assembling the structure of a Solar MMS assambly
Phase 1: Site Survey and Foundation

· Step 1: Conduct Site Assessment: Survey the land to ensure it is clear of underground utilities and overhead obstructions. The ground must be level enough to support the structure.
· Step 2: Establish Foundation:
· For Portable/ Temporary Masts: Position the concrete ballast blocks or the trailer base where the mast will be erected.
· For Permanent Masts: Dig the foundation pits according to the engineering plans. Pour concrete and install anchor bolts or a base plate for the mast. Allow time for the concrete to cure.

Phase 2: Base Frame and Tower Sections Assembly

· Step 3: Assemble the Base Section:
· If using a lattice tower structure, bolt the base section to the foundation anchor rods.
· If using a tilt-up tubular mast, assemble the hinge base plate onto the foundation.
· Step 4: Pre-Assemble Components (Ground Work):
· Lay out the remaining mast sections on the ground in order.
· Crucial Step: Before lifting, attach the solar panel mounting brackets, sensor arms, and any cable ladders to the mast sections while they are still at ground level. It is much safer and easier to do this now.

Phase 3: Solar and Instrumentation Pre-Installation

· Step 5: Mount the Solar Array:
· Attach the solar panel frame to the pre-installed brackets on the mast.
· Secure the photovoltaic (PV) panels to the frame. Do not connect the wiring fully yet, as the panels might generate power during lifting.
· Step 6: Attach Monitoring Equipment:
· Install the cross-arms for the meteorological sensors (anemometers, wind vanes, pyranometers for solar measurement).
· Mount the instrumentation enclosure (data logger box) onto the mast leg.

Phase 4: Er****on of the Structure

· Step 7: Rigging and Lifting:
· Attach a gin pole or a crane line to the top of the mast assembly.
· If using a tilt-up mast, attach the winch cables to the guy plate.
· Step 8: Raise the Mast:
· Slowly lift the mast into the vertical position.
· For guyed masts: Stop at intermediate guy wire attachment points. Attach the guy wires to their ground anchors and tension them slightly before continuing the lift.
· For self-supporting towers: Bolt the remaining sections as the crane lifts them into place.

Phase 5: Securing and Leveling

· Step 9: Final Securing:
· Once vertical, bolt the mast head fl**ge to the base section.
· Torque all bolts to the specifications provided in the engineering manual.
· Step 10: Tensioning (Critical Step):
· If the structure uses guy wires, use a tensiometer to ensure each guy wire is tensioned evenly according to the specifications. Uneven tension can cause the mast to collapse or sway, affecting solar sensor readings.

Phase 6: Final Assembly and Testing

· Step 11: Solar Wiring:
· Connect the solar panels to the charge controller inside the instrumentation enclosure.
· Connect the battery bank to the system.
· Step 12: Sensor Installation:
· Install the delicate solar sensors (pyranometers) on the sensor arms. Ensure they are perfectly level (using the bubble level on the sensor) and have an unobstructed view of the sky.
· Step 13: Lightning Protection:
· Ensure the lightning rod (if installed at the mast peak) is properly grounded with a low-resistance path to the ground rods.

15/03/2026

Solar Project Piling Work Construction Process (Ground Mount Solar)
Solar plant ( 100 MW / 300 MW) piling work foundation is very important part ,solar module structure

1️⃣ Survey & Layout Marking
•Site survey
•Pile location marking total station / GPS
• Grid layout making (example: 4m × 7m
module table spacing)

2️⃣ Soil Investigation

•Soil testing

•Soil bearing capacity

•Pile depth (1.5 m – 3 m typical)

•Soil type (hard / soft / rocky)

3️⃣ Pile Material Preparation

this Solar projects mostly GI / Hot Dip Galvanized Steel piles is use

Types:

C-Pile

H-Pile

U-Pile

Typical size:

80 mm – 150 mm width

Thickness 3–5 mm

4️⃣ Pile Driving (Main Construction Work)

This is important step

Machine used:

•Hydraulic Pile Driver

•Vibratory Hammer

•Impact Hammer

Process:

1. Machine pile location

2. Steel pile ground drive

3. Required depth hammering

Typical depth:

1500 mm – 2500 mm

5️⃣ Vertical Alignment Check

Pile verticality check

Spirit level / digital inclinometer use

Tolerance:

±2° normally allowed

6️⃣ Pile Cut-off Level

Top cutting

Required height maintain

7️⃣ Quality Inspection

Check points:

Pile depth

Verticality

Location accuracy

Galvanization damage

8️⃣ As-Built Survey

Installed piles is final survey

Coordinates record

9️⃣ Structure Installation Preparation

•Piling complete further

•Ramming / table structure installation start

and then solar modules install

Example Productivity (Solar Projects)

Typical output:

1 Pile driver machine: 250 – 400 piles/day

300 MW project: ~1,000,000 piles approx.

Solar Project Piling Activities (Planner / Primavera P6)

Typical activities:

1. Site survey

2. Layout marking

3. Pile material delivery

4. Pile driving

5. Verticality inspection

6. Pile cutting

7. Quality inspection

8. As-built survey

9. Handover for structure

Solar piling machine productivity calculation

solar construction workflow (piling →
structure → module → inverter) । 🚀

Sohaib Khan

19/04/2026

13/04/2026

06/04/2026

04/04/2026

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