Solid Solar Pvt. Ltd. has commissioned a ~20 MWp Solar Power Project in Malna/Patara village of Uttarkashi district, Uttarakhand, described as one of India’s largest solar plants built on a hilly terrain. Developed across a single hill at an elevation of more than 5000 feet above sea level the plant is powered by Gautam Solar’s TOPCon bifacial modules.
Building a solar plant of this scale on a single hill presented challenges far removed from those of a conventional flat solar site. The steep, rocky and uneven terrain, remote Himalayan location and limited accessibility meant that almost every stage of the project had to be adapted to the challenging terrain, harsh climatic conditions, wild life risks, logistical constraints and manpower limitations.
The first challenge was getting the plant layout right. Given the significant variations in elevation and terrain, Solid Solar created a detailed 3D model of the entire hill. This enabled the design and site teams to plan the placement of modules and supporting structures according to the actual contours, helping achieve a precise layout while making the best use of the available space and sunlight.
The terrain posed an equally difficult challenge once construction began, as most of the hill could not be accessed by conventional vehicles. To overcome this and numerous other challenges, Solid Solar developed several cost-effective and innovative solutions. Chief among them was a ropeway used to transport materials and solar modules across the most difficult sections of the site. Relying solely on manual material handling or using a conventional ropeway system would have involved both substantially higher costs and longer timelines. Where even the ropeway could not provide a practical solution, the teams relied on smaller, site-specific methods: a controlled sliding mechanism, a manpower-based chain-link system and, through the most difficult stretches of the hill, ‘kachhars’ (mules) to transport materials. These seemingly simple solutions played an important role in keeping construction moving across terrain where conventional logistics were not feasible.
The rocky ground presented another challenge as conventional heavy equipment used for piling and foundation work could not be deployed across almost the entire hill. Solid Solar therefore relied on portable handheld equipment to break and drill through rock, enabling teams to work in areas inaccessible to larger machinery. The project also used chemical grouting to secure columns. This technique, more commonly associated with rooftop solar applications, was adapted to suit the specific conditions of the rocky hillside.
Gautam Solar’s n-type TOPCon bifacial modules have been deployed across the project. The technology allows the modules to generate electricity from sunlight reaching both sides of the panel, bringing advanced solar technology to a project where module selection had to be suite to demanding site conditions. The plant has reportedly delivered stronger performance than several other solar installations in the surrounding region. While performance varies depending on site and operating conditions, these reported results add to the significance of a large-scale solar installation developed in such a terrain.
Mukesh Agrawal, Managing Director, Solid Solar Pvt. Ltd., said, “Building a plant of this scale on a single hill required meticulous planning, innovative thinking to develop out-of-the-box solutions and close coordination between the design and site engineering teams. The successful commissioning of our 20 MWp Solar PV Plant in Malna/Patara village is an important milestone for us and reflects the engineering effort that went into its execution. As the project neared completion, its scale and complexity attracted several visitors who came to see the solar plant, with some describing it as an ‘engineering marvel’ underscoring the exceptional complexity of developing a large-scale solar plant across a single, highly uneven hill.”
Commenting on the occasion, Gautam Mohanka, Managing Director, Gautam Solar Pvt. Ltd., said, “The Uttarkashi project demonstrates the potential for advanced solar technology to be deployed in challenging geographical conditions. Our TOPCon bifacial modules powering this project are part of an approach that combines technology with site-specific engineering and meticulous execution.”
The commissioning of the Uttarkashi project marks an important development in India’s renewable energy landscape. Beyond its 20 MWp capacity, the project stands as an example of how engineering, innovation and persistence can bring large-scale solar power to terrain where conventional approaches may not be suitable.
