EPC (Engineering, Procurement, Construction) Services

EPC (Engineering, Procurement, Construction) Services by Sigma Solutions

Introduction

A renewable energy company planned to establish a high-efficiency solar power plant but encountered challenges in engineering design, procurement logistics, and construction execution. Delays in sourcing critical components and navigating regulatory approvals posed significant risks. The client partnered with Sigma Solutions for full-scope EPC services to deliver the project on time, within budget, and in full compliance with all legal and technical standards.

Challenges Faced

1. Engineering & Design Optimization

The client required a solar plant layout that ensured maximum energy generation with terrain-specific efficiency.

2. Procurement Delays & Supply Chain Disruptions

Key components like inverters, solar modules, and transformers were delayed due to supplier bottlenecks and global logistics issues.

3. Cost Overruns & Budget Management

Rising prices for steel, electrical cabling, and labor created financial pressure and threatened profitability.

4. Regulatory & Safety Compliance

Approvals were required from the State Electricity Board, Environmental Control Boards, and compliance with IS standards, OSHA, and solar energy policies.

5. Construction Execution & On-Site Management

The client lacked the manpower, equipment, and execution strategy to manage civil, electrical, and grid-tie works efficiently.

Solution Provided by Sigma Solutions

Sigma Solutions delivered a comprehensive EPC solution—combining engineering excellence, vendor coordination, regulatory compliance, and site execution management.

Implementation Process

1. Engineering Design & Feasibility Analysis

Conducted solar irradiance and terrain analysis to determine optimal tilt and orientation.
Designed grid-compatible infrastructure including transformers, control rooms, and cabling paths.
Used advanced simulation software to forecast generation capacity and ROI.

2. Procurement Planning & Vendor Coordination

Partnered with Tier-1 solar panel, battery, and inverter manufacturers.
Negotiated bulk procurement contracts for cost savings and delivery prioritization.
Ensured all components met MNRE guidelines and IS 2062 material standards.

3. Cost Optimization & Budget Control

Performed value engineering to balance CAPEX with long-term OPEX efficiency.
Substituted costly imports with certified domestic components without quality compromise.
Implemented automated monitoring systems to reduce post-installation maintenance costs.

4. Regulatory Approvals & Compliance

Managed all submissions to State Electricity Boards, pollution boards, and local authorities.
Ensured zero-delay approvals through timely inspections and follow-ups.
Fulfilled all standards under National Solar Mission and IS/IEC solar safety norms.

5. Construction Execution & Site Supervision

Mobilized trained civil and electrical teams under full-time Sigma Solutions supervision.
Used real-time project tracking dashboards for status visibility and timeline adherence.
Ensured safe, OSHA-compliant installation with quality audits at each milestone.

Results Achieved

25% Faster Project Completion
Well-coordinated execution reduced construction delays and labor idle time.

20% Procurement & Construction Cost Savings
Efficient vendor deals and optimized resource utilization lowered capital expenditure.

100% Regulatory Compliance
All permits, clearances, and audits were passed without penalty or resubmission.

Optimized Solar Power Generation
The design yielded above-average plant load factor (PLF) and long-term ROI.

Seamless Grid Integration
The plant was successfully synchronized with the national grid and approved for feed-in.

Conclusion & Key Takeaways

A successful EPC execution requires more than just construction—it demands technical insight, procurement efficiency, and real-time project control. Sigma Solutions delivered an integrated EPC package that helped the client achieve early commissioning, cost control, and full regulatory approval—setting a benchmark in solar infrastructure execution.