Energy Management System design for a hybrid 35 MW Solar + 5 MW/10 MWh BESS plant, with cost-optimized BOM, multi-vendor evaluation, and comprehensive architecture design at 12% lower cost than competitors.
Skipper Limited, a leading Indian manufacturer of transmission & distribution structures, PVC pipes, and engineering plastics, engaged Ingro Energy to design and supply the Energy Management System for a hybrid Solar + BESS plant. The project integrates a 35 MW solar PV facility with a 5 MW / 10 MWh Battery Energy Storage System, with Ingro's EMS operating as a slave to the Plant Power Controller (PPC) which communicates with the State Load Dispatch Centre.
This project showcases Ingro's capability to deliver cost-optimized, standards-compliant EMS solutions for hybrid renewable energy plants, with detailed BOM engineering, multi-vendor evaluation, and comprehensive architecture design.
Multi-system coordination, Solar inverters, BESS PCS, BMS, HVAC, fire suppression, and grid protection from different OEMs must be unified
PPC hierarchy compliance, EMS as slave under the Plant Power Controller with precise IEC 61850, Modbus TCP, IEC-104 protocol implementation
2-Block architecture, each block requiring a field RCP connected to central MCP via fiber ring topology
BESS-specific I/O, BMS cell-level data via CAN-to-Modbus gateways, PCS parameters, HVAC, fire/gas detection sensors, and safety interlocks
Cost optimization pressure, lowest possible EMS cost without compromising reliability or compliance
Architecture Design: Complete OT network, MCP with redundant L3 switches, 2× RCPs, fiber ring backbone, FortiGate firewall, GPS time server, IEC-104 gateway
Comprehensive BOM: 10-sheet workbook with 239 formulas, zero errors, and 3-tier vendor alternatives for every component
BESS-Specific Integration: CAN-to-Modbus gateways for BMS, Pilz safety relays, additional I/O for HVAC and fire suppression
I/O Point Schedule: Mapped ~2,126 total tags across all devices, hardwired and protocol-based
Cost Optimization: Final BOM at ₹52.16 Lakhs (₹1.49L/MW), 12% lower than competing quote while covering 10 critical gaps
Manufacturing (T&D Structures, PVC), India
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