A metro rail construction contractor in Chennai was burning ₹80 lakh per year in diesel fuel across 8 gensets — with mounting noise complaints, air quality notices, and carbon penalty risk. TESAS deployed a mobile 800 kWh BESS + 400 kWp solar system that cut diesel use by 70% without disrupting the 24-hour construction schedule.
The elevated metro rail construction site stretched 4.2 km through urban Chennai with no grid power access at 6 of the 8 work zones. The contractor depended on 8 × 250 kVA diesel generators running 18–22 hours per day — consuming 4,200 litres of diesel daily during peak construction.
Beyond the ₹80 lakh annual fuel cost, the contractor faced: escalating fuel theft risk, 4 diesel storage areas requiring fire safety compliance, CPCB air quality notices for particulate emissions in a residential area, and difficulty attracting skilled workers due to constant generator noise.
TESAS designed a containerised mobile solar + BESS microgrid that functions as the primary power source from 6 AM to 6 PM (solar hours) and overnight (BESS discharge), with only 2 diesel gensets kept as emergency backup — down from 8.
TESAS engineers monitored existing genset runtime logs and designed a solar microgrid sized to supply 70% of daily kWh demand.
2 × 400 kWh BESS containers on flatbed-relocatable skids. 400 kWp of bifacial panels on galvanised frame — dismountable within 2 days for site moves.
TESAS microgrid controller manages solar priority → BESS dispatch → genset start — diesel only fires if BESS SoC drops below 15% at night.
Daily fuel consumption report, solar generation dashboard, and genset runtime alerts via WhatsApp to site manager.
| Parameter | Specification |
|---|---|
| Solar PV | 400 kWp, bifacial monoPERC, 580W modules |
| BESS Capacity | 800 kWh (2 × 400 kWh containers) |
| Battery Chemistry | LFP, rack-mounted |
| Inverter / PCS | 3 × 200 kW bidirectional hybrid inverters |
| Microgrid Controller | TESAS MGC-200, SCADA + IoT |
| Backup Gensets (reduced) | 2 × 250 kVA (from 8) |
| Peak Surge Capacity | 800 kW (2-second), 600 kW sustained |
| Enclosure Rating | IP55, −10°C to +55°C |
| Relocation Time | 2 days per site move |
| Diesel Avoided | 1,0,85,000 litres |
| CO₂ Avoided | 480 tCO₂e |
| NOx Reduction | ~2.4 tonnes |
| PM2.5 Reduction | ~180 kg |
| Noise Reduction | −22 dB at site boundary |
| System CAPEX | ₹2.2 Crore (lease option available) |
| Diesel Cost Saved | ₹80 Lakh/year |
| O&M | ₹5 Lakh/year |
| Net Annual Saving | ₹75 Lakh |
| Payback | ~35 months |
"Our CPCB air quality notice was the trigger to look at alternatives. TESAS delivered a system that not only fixed the compliance issue but actually saves us money every month. The mobility feature is critical for us — we've already relocated the system once and it took just two days."
Whether you have grid access or not — TESAS designs solar-BESS microgrids that work for construction timelines and mobile site requirements.