2.48 MWp Solar PV Detailed Design for an Automotive Manufacturing Site
PVSol rooftop solar PV layout for a 2.48 MWp system designed across multiple roof areas on a large automotive manufacturing site.
Nortcel was asked to develop a detailed solar PV design for a large automotive manufacturing site in North East England, following an earlier preliminary design.
The client wanted to increase the system capacity where possible, review additional flat roof areas, allow for future removal of rooftop obstructions and compare different layout approaches for seasonal generation.
The challenge
The project had multiple roof areas, rooftop obstructions, access routes and uncertainty around which mechanical services would be removed before installation.
The design also needed to consider the existing Mansafe layout, possible use of skylight areas, and the balance between maximising installed capacity and maintaining a practical roof layout.
The solution
Nortcel developed a 2.48 MWp rooftop solar PV design across multiple roof zones.
The design used 5,511 Trina Solar modules and a SolaX inverter architecture. Different layout approaches were reviewed, including generation-focused and winter-performance-focused options. A 10° mounting angle was identified as the most practical balance between capacity, performance, shading and wind loading.
Project results
The PVSol simulation estimated annual solar generation of 2,399,021 kWh / year.
The model showed 1,965,013 kWh / year used onsite and 434,008 kWh / year exported to the grid. This resulted in 81.9% own power consumption and 15.7% self-sufficiency.
Estimated avoided emissions were 551,447 kg CO₂ / year.
Energy profile
Annual energy profile showing onsite PV use, grid export and consumption coverage for the 2.48 MWp rooftop solar PV design.
The energy profile shows how the annual PV generation is split between onsite use and grid export. It also shows how the system contributes to the site’s wider manufacturing electricity demand.
Design outcome
The design increased the available PV capacity from the earlier concept stage and provided a more detailed basis for review, including module layout, inverter strategy, roof-by-roof assumptions and practical installation constraints.
The output supported client review, structural coordination, mounting assessment and next-stage project development.
Key figures
System size: 2.48 MWp
Annual generation: 2,399,021 kWh / year
Modelled annual consumption: 12,544,469 kWh / year
Own power consumption: 81.9%
Self-sufficiency: 15.7%
Grid export: 434,008 kWh / year
CO₂ avoided: 551,447 kg / year
PV modules: 5,511 Trina Solar modules
Inverters: 29 SolaX inverters
Battery storage: Not included
Design stage: Detailed rooftop solar PV design
